ABB Product Manual Procedures IRB2400 Part 1

Product manual (part 1 of 2), proceduresArticulated robotIRB 2400 - L

IRB 2400 - 10

IRB 2400 - 16

M2000,M2000A, M2004

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Product manual, (part 1 of 2), procedures

Articulated robot

IRB 2400 - L

IRB 2400 - 10

IRB 2400 - 16 M2000

M2000A

M2004

Document ID: 3HAC 022031-001

Revision: A

The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB’s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

© Copyright 2004 ABB All right reserved.

ABB Automation Technologies ABRobotics

SE-721 68 Västerås Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Safety 13

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 311.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2 Installation and commissioning 41

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422.2.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422.2.2 Working range, IRB 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462.3.1 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472.3.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492.3.4 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552.4.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582.4.4 Limiting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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Table of Contents

3 Maintenance 61

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.2 Maintenace schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.3 Changing activites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643.3.1 Change of oil in wrist unit IRB 2400/10/16 /L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643.3.2 Change the backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4 Repair 71

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.3.1 Removal of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.3.2 Refitting of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 934.4.1 Removal of wrist IRB 2400/10/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 934.4.2 Refitting of wrist IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 964.4.3 Removal of wrist IRB 2400L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 994.4.4 Refitting of wrist IRB 2400L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024.4.5 Removal of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1044.4.6 Reassemble of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1104.5.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1104.5.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1144.5.3 Removal of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1174.5.4 Reassemble of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1234.6.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1234.6.2 Reassemble of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1274.6.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1314.6.4 Reassemble of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1334.6.5 Removal of the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1354.6.6 Reassemble of the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1404.7.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1404.7.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1434.7.3 Removal of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1454.7.4 Refitting of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1484.7.5 Removal of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1524.7.6 Refitting of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1554.7.7 Removal of motor, axis 4-6;IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1594.7.8 Refitting of motor, axis 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1624.7.9 Removal of motor, axis 4-6, IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1674.7.10 Refitting of motor, axis 4-6 IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1744.8.1 Removal of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1744.8.2 Refitting of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1764.8.3 Remove the complete drive mechanism. IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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Table of Contents

4.8.4 Refitting of complete drive mechanism. IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5 Calibration information 183

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1835.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1845.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1865.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1885.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1895.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193


Overview

Overview

About this manual

This manual contains instructions for

• mechanical and electrical installation of the manipulator

• maintenance of the manipulator

• mechanical and electrical repair of the manipulator.

Usage

This manual should be used during

• installation, from lifting the manipulator to its work site and securing it to the

foundation 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.

Prerequisites

The reader should...

• be a trained maintenance/repair craftsman

• have the required knowledge of mechanical and electrical installation/repair/

maintenance work.

Organization of chapters

The manual is organized in the following chapters:

Chapter Contents

Safety, service Safety information

Installation and commissioning Information about installation of the manipulator.

Maintenance Information about maintenance work, including maintenance schedules.

Repair Information about repair work.

Calibration information Procedures that do not require specific calibration equipment. General information about calibration.

Decommissioning Environmental information about the manipulator.


Overview

References

Revisions

Reference Document Id

Revision Description

- 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.

A Chapter“ Calibration” replaced with chapter “Calibration information”.

Safety chapter rewritten.


How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material etc. The references are read as

described below.

References to figures

The procedures often include references to components or attachment points located on the

robot/controller. The components or attachment points are marked with italic text in the

procedures and completed with a reference to the figure where the current component or

attachment point is shown.

The denomination in the procedure for the component or attachment point corresponds to the

denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in an procedure.

References to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the

different actions in the procedure. The equipment is marked with italic text in the procedures

and completed with a reference to the section where the equipment is listed with further

information, i.e. article number, dimension.

The denomination in the procedure for the component or attachment point corresponds to the

denomination in the referenced list.

The table below shows an example of a reference to a list of required equipment, from a step

in an procedure.

Safety information

The manual includes a separate safety chapter that must be read through before proceeding

with any service or installation procedures. All procedures also include specific safety

information when dangerous steps are to be performed. Read more in chapter Safety on page

13.

Step Action Note/Illustration

8. Remove the rear attachment screws, gearbox. Shown in the figure Location of gearbox on page xx.


3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required equipment on page xx.


Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

General

The complete product documentation kit for the M2000 robot system, including controller,

robot and any hardware option, consists of the manuals listed below:

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which

is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

• Maintenance (descriptions of all required preventive maintenance procedures

including intervals)

• Repair (descriptions of all recommended repair procedures including spare parts)

• Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

• Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)

• Part list

• Foldouts or exploded views

• Circuit diagrams

Software manuals

The software documentation consists of a wide range of manuals, ranging from manuals for

basic understanding of the operating system to manuals for entering parameters during

operation.

A complete listing of all available software manuals is available from ABB.

Controller hardware option manual

Each 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, M2004


General

The robot documentation may be divided into a number of categories. This listing is based on

the type of information contained within the documents, regardless of whether the products

are standard or optional. This means that any given delivery of robot products will not contain

all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for

M2004 robot systems.

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which

is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

• Maintenance (descriptions of all required preventive maintenance procedures

including intervals)

• Repair (descriptions of all recommended repair procedures including spare parts)

• Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

• Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)

• Part list

• Foldouts or exploded views

• Circuit diagrams

RobotWare manuals

The following manuals describe the robot software in general and contain relevant reference

information:

• RAPID Overview: An overview of the RAPID programming language.

• RAPID reference manual part 1: Description of all RAPID instructions.

• RAPID reference manual part 2: Description of all RAPID functions and data types.

• Technical reference manual - System parameters: Description of system

parameters and configuration workflows.

Application manuals

Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful)

• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)



• How to use the application

• Examples of how to use the application

Operator’s manuals

This group of manuals is aimed at those having first hand operational contact with the robot,

i.e. production cell operators, programmers and trouble shooters. The group of manuals

include:

• Operator’s manual - IRC5 with FlexPendant

• Operator’s manual - RobotStudioOnline

• Trouble shooting Manual for the controller and robot

Miscellaneous

A number of manuals provide generic descriptions of the robot and robot system. These

include:

• Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)




1 Safety

1.1. Introduction

1 Safety

1.1. Introduction

Overview

The safety information in this manual is divided in two categories:

• general safety aspects, important to attend to before performing any service work on

the robot. These are applicable for all service work and are found in section General

safety information on page 14.

• specific safety information, pointed out in the procedure at the moment of the danger.

How to avoid and eliminate the danger is either detailed directly in the procedure, or

further detailed in separate instructions, found in section Safety related instructions on

page 34.


1 Safety

1.2.1. Introduction

1.2 General safety information

1.2.1. Introduction

Definitions

This section details general safety information for service personnel i.e. personnel performing

installation, repair and maintenance work.

Sections

The general safety information is divided into the following sections:

1. General information contains lists of:

• Safety, service

• Limitation of liability

• Referenced documents

2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split

into different categories:

• Safety risks during service work on robot

• Safety risks related to gripper/end effector

• Safety risks related to tools/workpieces

• Safety risks related to pneumatic/hydraulic systems

• Safety risks during operational disturbances

• Safety risks during installation and service

• Risks associated with live electric parts

3. Safety actions details actions which may be taken to remedy or avoid dangers.

• Safety fence dimensions

• Fire extinguishing

• Emergency release of the manipulator´s arm

• Brake testing

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

• Safe use of the Teach Pendant Unit enabling device

• Work inside the manipulator´s working range

• Signal lamp (optional)


1 Safety

1.2.2.1. Safety, service

1.2.2. General information

1.2.2.1. Safety, service

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor

does it cover all peripheral equipment, which can influence the safety of the total system. To

protect personnel, the complete system must be designed and installed in accordance with the

safety requirements set forth in the standards and regulations of the country where the robot

is installed.

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws

and regulations in the country concerned are observed and that the safety devices necessary

to protect people working with the robot system have been designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of the

industrial robot, described in the applicable documents, e.g. User’s Guide and Product

Manual.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the

connection of external safety devices. Via this interface, an external safety function can

interact with other machines and peripheral equipment. This means that control signals can

act on safety signals received from the peripheral equipment as well as from the robot.

In the Product Manual - Installation and Commissioning, instructions are provided for

connecting safety devices between the robot and the peripheral equipment.


1 Safety

1.2.2.2. Limitation of Liability

1.2.2.2. Limitation of Liability

General

Any information given in this manual regarding safety, must not be construed as a warranty

by ABB that the industrial robot will not cause injury or damage even if all safety instructions

have been complied with.


1 Safety

1.2.2.3. Related information

1.2.2.3. Related information

General

The list below specifies documents which contain useful information:

Documents

Type of information Detailed in document Section

Installation of safety devices Product manual for the manipulator

Installation and commissioning

Changing robot modes User’s Guide Start-up

Restricting the working space Product manual for the manipulator

Installation and commissioning


1 Safety

1.2.3.1. Safety risks during service work on robot

1.2.3. Safety risks


Overview

This section includes information of general safety risks to be considered when performing

service work on the robot.


1 Safety


Complete robot

Cabling

Gearboxes and motors

Safety risk Description

Hot components!

Caution!

Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns!

Removed parts may result in collaps of robot!

Warning!

Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.


Cable packs are sensitive to mechanical damage!

Caution!

The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!


Gears may be damaged if excessive force is used!

Caution!

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


1 Safety


Balancing device


Dangerous balancing device!

Warning!

Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!


1 Safety

1.2.3.2. Safety risks related to gripper

1.2.3.2. Safety risks related to gripper

CAUTION!

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


1 Safety

1.2.3.3. Safety risks related to tools/workpieces

1.2.3.3. Safety risks related to tools/workpieces

Safe handling

It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards

remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Grippers/end effectors must be designed so that they retain workpieces in the event of a power

failure or a disturbance of the controller.


1 Safety

1.2.3.4. Safety risks related to pneumatic/hydraulic systems

1.2.3.4. Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

• Residual energy may be present in these systems so, after shutdown, particular care

must be taken.

• The pressure in pneumatic and hydraulic systems must be released before starting to

repair them.

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 Safety

1.2.3.5. Safety risks during operational disturbances

1.2.3.5. Safety risks during operational disturbances

General

• The industrial robot is a flexible tool which 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 personnel

• Remedial action must only be carried out by qualified personnel who are familiar with

the entire installation as well as the special risks associated with its different parts.

Extraordinary risks

If the working process is interrupted, extra care must be taken due to risks other than those

associated with regular operation. Such an interruption may have to be rectified manually.


1 Safety

1.2.3.6. Safety risks during installation and service

1.2.3.6. Safety risks during installation and service

General risks during installation and service

• The instructions in the Product Manual - Installation and Commissioning must always

be followed.

• Emergency stop buttons must be positioned in easily accessible places so that the robot

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 robot must have the appropriate training for the robot system in

question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the robot system, the regulations

applicable in the country concerned and the instructions of ABB Robotics must be complied

with.

Non-voltage related risks

• Safety zones, which have to be crossed before admittance, must be set up in front of

the robot's working space. Light beams or sensitive mats are suitable devices.

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

space.

• The axes are affected by the force of gravity when the brakes are released. In addition

to the risk of being hit by moving robot parts, you run the risk of being crushed by the

parallel arm.

• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be

released if the robot, or parts thereof, is dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.

• Be aware of stored heat energy in the controller.

• Never use the robot as a ladder, i.e. do not climb on the robot motors or other part

during service work. There is a serious risk of slipping because of the high temperature

of the motors or oil spills that can occur on the robot.

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 standards for that function.

• The supplier of the complete system must ensure that all circuits used in the

emergency stop function are interlocked in a safe manner, in accordance with the

applicable standards for the emergency stop function.


1 Safety

1.2.3.7. Risks associated with live electric parts

1.2.3.7. Risks associated with live electric parts

Voltage related risks, general

• Although troubleshooting may, on occasion, have to be carried out while the power

supply is turned on, the robot must be turned off (by setting the mains switch to OFF)

when repairing faults, disconnecting electric leads and disconnecting or connecting

units.

• The mains supply to the robot must be connected in such a way that it can be turned

off outside the robot’s working space.

Voltage related risks, controller

A danger of high voltage is associated with the following parts:

• Be aware of stored electrical energy (DC link) in the controller.

• Units inside the controller, e.g. I/O modules, can be supplied with power from an

external source.

• The mains supply/mains switch

• The power unit

• The power supply unit for the computer system (230 VAC)

• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

• The drive unit (700 VDC)

• The service outlets (115/230 VAC)

• The power supply unit for tools, or special power supply units for the machining

process

• The external voltage connected to the control cabinet remains live even when the robot

is disconnected from the mains.

• Additional connections

Voltage related risks, robot

A danger of high voltage is associated with the robot 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

Installation and Commissioning Manual)

Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the OFF

position. Power supply cables which are in motion during the working process may be

damaged.


1 Safety

1.2.4.1. Safety fence dimensions

1.2.4. Safety actions

1.2.4.1. Safety fence dimensions

General

Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning

Dimension the fence or enclosure to enable it to withstand the force created if the load being

handled by the robot is dropped or released at maximum speed. Determine the maximum

speed from the maximum velocities of the robot axes and from the position at which the robot

is working in the work cell (see Product Specification - Description, Robot Motion).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating

tool or other device fitted to the manipulator.


1 Safety

1.2.4.2. Fire extinguishing

1.2.4.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator

or controller)!


1 Safety

1.2.4.3. Emergency release of the robot’s arm

1.2.4.3. Emergency release of the robot’s arm

Description

In an emergency situation, any of the robot’s axes may be released manually by pushing the

brake release buttons on the robot or on an optional external brake release unit.

How to release the brakes is detailed in section:

• Manually releasing the brakes on page 47.

The robot arm may be moved manually on smaller robot models, but larger models may

require using an overhead crane or similar.

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the

pressure on the trapped person, further increasing any injury!


1 Safety

1.2.4.4. Brake testing

1.2.4.4. Brake testing

When to test

During operation the holding brakes of each axis motor wear normally. A test may be

performed to determine whether the brake can still perform its function.

How to test

The function of each axis’ motor holding brakes may be checked as detailed below:

1. Run each manipulator axis to a position where the combined weight of the manipulator

arm and any load is maximized (max. static load).

2. Switch the motor to the MOTORS OFF position with the Operating mode selector 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 Safety

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

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

NOTE!

Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant

Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.


1 Safety

1.2.4.6. Safe use of the Teach Pendant Unit

1.2.4.6. Safe use of the Teach Pendant Unit

NOTE!

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)

which, when pressed halfway in, takes the system to MOTORS ON. When the enabling

device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

To ensure safe use of the Teach Pendant Unit, the following must be implemented:

• The enabling device must never be rendered inoperative in any way.

• During programming and testing, the enabling device must be released as soon as

there is no need for the robot to move.

• The programmer must always bring the Teach Pendant Unit with him/her, when

entering the robot's working space. This is to prevent anyone else taking control over

the robot without the programmer knowing.


1 Safety

1.2.4.7. Work inside the manipulator’s working range

1.2.4.7. Work inside the manipulator’s working range

WARNING!

If work must be carried out within the robot’s work envelope, the following points must be

observed:

• The operating mode selector on the controller must be in the manual mode position to

render the enabling device operative and to block operation from a computer link or

remote control panel.

• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in

position < 250 mm/s. This should be the normal position when entering the working

space. The position 100% ”full speed” may only be used by trained personnel who are

aware of the risks that this entails.

• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in

order not to get entangled with hair or clothing. Also be aware of any danger that may

be caused by rotating tools or other devices mounted on the manipulator or inside the

cell.

• Test the motor brake on each axis, according to section Brake testing on page 30.


1 Safety

1.3.1. Safety signals, general

1.3 Safety related instructions


General

This section specifies all dangers that may arise from performing the work detailed in the

manual. Each danger is detailed in its own section consisting 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 does not eliminate the danger.

• An instruction of how to eliminate the danger to facilitate performing the activity at

hand.

Danger levels

The table below defines the captions specifying the danger levels used throughout this

manual.

Symbol Designation Signification

danger

DANGER Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

warning

WARNING Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

Electrical shock

ELECTRICAL SHOCK

The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.

caution

CAUTION Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.


1 Safety


Electrostatic discharge (ESD)

ELECTROSTATIC DISCHARGE (ESD)

The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.

Note

NOTE Note symbols alert you to important facts and conditions.

Tip

TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Symbol Designation Signification


1 Safety

1.3.2. DANGER - Moving manipulators are potentially lethal!

1.3.2. DANGER - Moving manipulators are potentially lethal!

Description

Any moving manipulator is a potentially lethal machine.

When running the manipulator, it may perform unexpected and sometimes irrational

movements. However, all movements are performed with great force and may seriously

injure any personnel and/or damage any piece of equipment located within the manipulator

working range.

Elimination

Step Action Info/Illustration

1. Before attempting to run the manipulator, make sure all emergency stop equipment has been correctly installed and connected.

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

2. If possible, use the hold-to-run button whenever possible.

The hold-to-run button is used in manual mode, not in automatic mode.

How to use the hold-to-run control in RobotWare 5.0 is detailed in section How to use the hold-to-run switch in the Operator’s Manual, IRC5.

How to use the hold-to-run control in RobotWare 4.0 is detailed in section The Teach Teach Pendant unit in the User’s Guide.

3. Make sure no personnel is present within the manipulator working range before pressing the start button.


1 Safety

1.3.3. WARNING - The unit is sensitive to ESD!

1.3.3. WARNING - The unit is sensitive to ESD!

Description

ESD (electro static discharge) is the transfer of electrical static charge between two bodies at

different potentials, either through direct contact or through an induced electrical field. When

handling parts or their containers, personnel not connected to ground potential may transfer

high static charges. This discharge may destroy sensitive electronics.

Elimination

Assemble the wrist strap

The picture illustrates how the ESD wrist strap is assembled in the controller cabinet.

xx0400001055


1. Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

2. Use an ESD protective floor mat. The mat must be grounded through a current-limiting resistor.

3. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded.

A The strap is fastened to a button on the side of the control cabinet.

B When not used, the wrist strap is placed on the power supply unit.

C Power supply unit


1 Safety

1.3.4. WARNING - Safety risks during work with gearbox oil


Description

When handling the gearbox oil, there are several dangers to both personal injuries and product

damages! Following safety information must be regarded before performing any work with

the oil in the gearboxes!

Warnings and elimination

Warning Description Elimination / Action

-

Hot oil!

Changing and draining gearbox oil may require handling hot oil of up to 90 °C!

Make sure that protective gear like goggles and gloves are always worn during this activity.

-

Possible pressure build up in gearbox!

When opening the oil plug, there may be pressure present in the gearbox, causing oil to spray from the opening!

Open oil plug carefully and keep away from the opening. Do not overfill the gearbox when filling.

-

Do not overfill!

Overfilling of gearbox oil can lead to internal over-pressure inside the gearbox which in turn may:

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the manipulator from moving freely.

Make sure not to overfill the gearbox when filling with oil!

After filling, check the correct oil levels as described in section .

-

Do not mix types of oil!

Mixing types of oil may cause severe damage to the gearbox!

When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer!


1 Safety


-

Heat up the oil!

Warm oil drains quicker than cold oil.

When changing gearbox oil, first run the robot for a time to heat up the oil.

-

Specified amount depends on drained volume!

The specified amount of oil is based on the total volume of the gearbox. When changing the oil, the amount of refilled oil may differ from the specified amount, depending on how much oil has previously been drained from the gearbox.

After refilling, check the oil level as described in section .

Warning Description Elimination / Action


1 Safety



2 Installation and commissioning

2.1. Introduction


2.1. Introduction

General

This chapter contains information for installing the robot to the working site.

More detailed technical data, such as load diagram, permitted extra loads (equipment) and

location of extra loads (equipment), may be found in the Product Specification for the robot.



2.2.1. Pre-installation procedure

2.2 Unpacking


General

These instructions are to be used when unpacking and installing the robot for the first time.

They also contain information useful later during re-installation of the manipulator.

Checking the pre-requisites for installation

The check-list below details what must be observed before proceeding with the actual

installation of the manipulator:

1. Make sure only qualified installation personnel conforming to all national and local codes

are allowed to perform the installation.

2. Make sure the manipulator is not damaged, by visually inspecting it.

3. Make sure the lifting device to be used is fit to handle the weight of the manipulator as

specified in Weight on page 42.

4. If the manipulator is not to be installed directly, it must be stored as described in Storage

conditions on page 43.

5. Make sure the appointed operating environment of the manipulator conforms to the

specifications outlined in Operating conditions on page 43.

6. Before taking the manipulator to the installation site, make sure the site conforms to Loads

on foundation on page 42, Requirements on foundation on page 43 and Protection classes

on page 43.

7. When these prerequisites are met, the manipulator may be taken to its installation site as

described in Lifting manipulator with lifting slings on page 46.

Weight

The net weight of the manipulator is approximately: 380 kg.

Loads on foundation

The table below shows the different forces and torques working on the manipulator during

various kinds of operation.

Note! These forces and torques are extreme values that are rarely encountered during

operation. The values also never simultanesously reach their maximum!

IRB 2400 -10, -16

Forces and torquesEndurance load (operation)

Max. load (emergency stop)

Force xy (upright/suspended)

± 2000 N ± 2600 N

Force z (upright) 4100 ± 1400 N 4100 ± 1900 N

Forze z (suspended) - 4100 ± 1400 N - 4100 ± 1900 N

Torque Mxy ± 3400 Nm ± 4000 Nm

Torque Mz ± 550 Nm ± 900 Nm




IRB 2400 - L

Requirements on foundation

The table below shows the requirements of the foundation where the manipulator is to be

fitted:

Storage conditions

The table below shows the allowed storage conditions for the manipulator:

Operating conditions

The table below shows the allowed operating conditions for the manipulator and controller:

Protection classes

The table below shows the protection class of the main parts of the robot system:

Forces and torquesEndurance load (operation)

Max. load (emergency stop)

Force xy ± 1700 N ± 2100 N

Force z, upright 4100 ± 1100 N 4100 ± 1400 N

Force z, suspended - 4100 ± 1100 N - 4100 ± 1400 N

Torque Mxy ± 3000 Nm ± 3400 Nm

Torque Mz ± 450 Nm ± 900 Nm

Requirement Value

Min. levelity 0.5 mm

Max. tilt 5°

Min. resonance frequency 30 Hz

Parameter Value

Max. ambient temperature, storage +55° C

Max. ambient temperature, storage (less than 24 hrs) +70° C

Min. ambient temperature, storage -25° C

Max. ambient humidity, storage Max. 95% at constant temperature

Parameter Value

Max. ambient temperature +45° C

Min. ambient temperature +5° C

Max. ambient humidity Max. 95% at constant temperature

Equipment Protection class

Manipulator IP 67



2.2.2. Working range, IRB 2400


Working range axis 2-3

This section details the working area of IRB 2400.

IRB 2400L

The working area is the same for both floor and inverted (suspended). Positions at wrist

center.

xx0200000159

Pos. Angle axis 3

X Z Angle axis 2

0

0

970 1620 0

1

-60

404 2298 0

2

65

602 745 0

3

-60

1577 -246 110

4

24,5

400 -403 110

5

-60

-1611 623 -100

6

65

-115 1088 -100




2400/10, 16

The working area is the same for both floor and inverted (suspended). Positions at wrist

center.

xx0200000160

Pos. Angle axis 3

X Z Angle axis 2

0

0

855 1455 0

1

-60

360 2041 0

2

65

541 693 0

3

-60

1351 -118 110

4

18,3

400 -302 110

5

-60

-1350 624 -100

6

65

-53 1036 -100



2.3.1. Lifting manipulator with lifting slings

2.3 On-site installation

2.3.1. Lifting manipulator with lifting slings

General

This section details how to lift the manipulator using lifting slings.

Illustration

The following figure shows how to lift the manipulator with lifting slings.

xx0200000164

How to lift the manipulator

1. Release the brakes according to the section, “manualy releasing the brakes”.

2. Adjust the manipulator to lifting position according to the picture.

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

Equipment Note

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



2.3.2. Manually releasing the brakes


General

he section below details how to release the holding brakes of each axis’ motor.

This may be done in one of three ways:

• using the pushbutton when the manipulator is connected to the controller.

• using the pushbutton on the manipulator with an external power supply.

• using an external voltage supply.

DANGER!

When pushing the button all axes are released, the axes become activated very quickly and

the robot may collapse in an unexpected way and cause damage or personal injury.

Using the pushbutton when the manipulator is connected to the controller

This section details how to release the holding brakes using the internal brake release unit.


1. Push the "brake release button" to release the holding brakes, see following illustration.

xx0200000168

• A: Pushbutton




Using the pushbutton on the manipulator with an external power supply

This section details how to release the holding brakes with the pushbutton using an external

voltage supply.

CAUTION!

Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can

be caused to a resistor diode and to the system board.


1. Connect an external power supply to connector XP1 as shown in the following illustration.

xx0200000167

• A: R1.MP

• B: Push button

• C: B8 = +24 V

• D: C10 = 0V

2. Push the "brake release button" to release the holding brakes, see the previous illustration.



2.3.3. Orienting and securing the manipulator


General

This section details how to orient and secure the manipulator to the foundation in order to

safely run the robot. The requirements for the foundations are shown in the tables and figures

below.

Bolting requirements

When bolting a mounting plate or frame to a concrete floor, follow the general instructions

for expansion-shell bolts. The screw joint must be able to withstand the stress loads difined

in section “Loads on foundation”.

NOTE!

When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must

be used to secure the bolted joint.

Attachment screws

The table below specifies the type of securing screws and washers to be used for securing the

manipulator to the base plate/foundation.

Hole configuration

The illustration below shows the hole configuration used when securing the manipulator:

xx0200000181

Suitable screws, lightly lubricated: M16 x 50

Quality Quality 8.8

Suitable washer: Thickness: 3 mm

Outer diameter: 30 mm

Inner diameter: 17 mm

Tightening torque: 190 Nm




Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes:

xx0200000182

Guide bushings

Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be

remounted without re-adjusting the program.

Equipment Art. no.

Guide sleeves 2151 0024-169



2.3.4. Suspended mounting


General

The IRB 2400 robot can be mounted in a suspended position, following information is to be

consider when turning the manipulator.

Turning the manipulator

1. Use the special tool for inverted mounting, see following illustration.

xx0200000212

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

A Lifting beam

B Fork lift

- Inverted mounting tool 3HAC 8961-1




xx0200000215

A Plastic plugs (x8)



2.3.5. Loads

2.3.5. Loads

General

Any loads mounted on the manipulator must be defined correctly and carefully (with regard

to the position of center of gravity and inertia factor) in order to avoid jolting movements and

overloading the motors. If this is not done correctly operational stops may result.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the

Product Specification. The loads must also be defined in the software as detailed in User’s

Guide (RobotWare 4.0), or Operator’s manual (RobotWare 5.0).

Stop time and braking distances

Manipulator motor brake performance depends on any loads attached. For further

information about brake performance, please contact ABB Robotics.



2.4.1. Introduction

2.4 Restricting the working range

2.4.1. Introduction

General

When installing the robot, make sure that it can move freely within its entire working space.

If there is a risk that it may collide with other objects, its working space should be limited.

The working range of the robot may be limited to eliminate the risk of collisions. The

following axes may be restricted:

• Axis 1, hardware (mechanical stop) and software (signal from adjustable position

switch)


switch)


switch)

This section describes the use of the mechanical stops and/or the position switches.

Notice that adjustments must be made also in the software, references to software manuals

are given in following installation procedures.



2.4.2. Mechanically restricting the working range of axis 1


General

The axis 1 working range may be restricted mechanically.

Stops

The working range may be restricted by fitting a mechanical stop.

If the robot should run into one of these stops during operation, the mechanical stop pin and

the extra moveable mechanical stop arm for axis 1 must be replaced!

xx0200000205

Mounting extra stops

The section below shows how to mounting an extra mechanical stop.

Pos. Description Article number

A Hex socket head cap screw 9ADA 183-65

B Plain washer 9ADA 312-9

C Removable stop axis 1 3HAC 7310-1

1 Stop axis 1. removable

2 Plain washer

3 Hex socket head cap screw


1. Make a copy of the drilling pattern.

2. Mark out the location of the holes on each stop.

3. Drill the holes through, 10.2 cut threads, M12.

4. Mount the stops without tightening the screws.

5. Turn axis 1 manually and check the working range between the stops.

If necessary correct the angle of impact.




Drilling pattern for extra stops

Pictures shows the drill pattern to be used when drilling for mechanical stops on axis 1.

xx0200000206




Drill pattern

xx0200000207





General

The range of rotation for axis 2 can be limited mechanically by fitting extra stops on the lower

arm.

xx0200000208

Number of parts and angles

Number of parts needed for different angles are shown in the table below. Item numbers

refering to the previous illustration.

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

+110° / -100° - - -

+110° / -70° 1 2 2

+110° / -40° 2 2 4

+80° / -100° 1 2 2

+80° / -70° 2 2 4

+80° / -40° 3 2 6

+50° / -100° 2 2 4

+50° / -70° 3 2 6

+50° / -40° 4 2 8

+20° / -100° 3 2 6

+20° / -70° 4 2 8

+20° / -40° 5 2 10



2.4.4. Limiting the working range of axis 3


General

The working range of axis 3 can be limited by fitting an electrical switch on the gear box axis

3, which senses the position via a cam.

Mounting of eletrical stop

Following illustration shows howe to mount the electrical stop.

xx0200000211





3 Maintenance

3.1. Introduction

3 Maintenance

3.1. Introduction

Structure of this chapter

This chapter details all maintenance activities recommended for the robot and any external

units of the robot.

It is based on the maintenance schedule, located in the beginning of the chapter. The schedule

contains information about required maintenance activities including periodicity and refers to

procedures for the activities.

Each procedure contains all information required to perform the activity, e.g. required tools

and materials.

The procedures are gathered in different sections, divided according to the maintenance

activity.

Safety information

Before any service work is commenced, it is extremely important that all safety information

is observed!

There are general safety aspects that must be read through, as well as more specific safety

information that describe danger and safety risks when performing the procedures. Make sure

to read through the chapter Safety on page 13.


3 Maintenance

3.2.1. Specification of maintenance intervals

3.2 Maintenace schedule

3.2.1. Specification of maintenance intervals

Description

The intervals may be specified in different ways depending on the type of maintenance

activity to be carried out and the working conditions of the robot:

• Calendar time: specified in months regardless of whether the robot system is run or not

• Operating time: specified in operating hours. More frequent running of the robot

means more frequent maintenance activities.


3 Maintenance

3.2.2. Maintenance schedule

3.2.2. Maintenance schedule

General

The robot must be maintained regularly to ensure proper function. The maintenance activities

and intervals are specified in the table below.

Non-predictable situations also give rise to inspections of the robot. Any damages must be

attended to immediately!

The inspection intervals do not specify the life of each component.

Activities and intervals, standard equipment

The sections referred to in the table can be found in the varius chapters for each maintenance

activity.

The table below specifies the required maintenance activities and intervals:

1. Change the oil for the first time after 4,000 h, then after every 60 month.

2. Valid interval if the robot is working in an environment temperature over 40ºC.

3. The battery is used as a back-up when the robot system is switched off. Therefore, the

life of a lithium battery depends on how frequently the power to the system is switched

off and also if the environment temperature is higher than recommended operating

temperature. The life varies from 12 - 36 mths, depending on current conditions. An

alert is given on the TPU when the battery is nearly discharged and it must then be

replaced within a month.

Maintenance activity

Interval Note Detailed in section:

Oil change in wrist unit

After first 4,000 h, then every 60 mth.1

12,000 h2

Change of oil in wrist unit IRB 2400/10/16 /L on page 64

Change of back-up battery for SMB unit

12-36 mths 3 Measuring the capacity of the battery backup unit to the SMB

Change the backup battery on page 67

Inspection of all signal cabling in lower and upper arm

36 mths Replace if required.

Replacement of mechanical stop axis 1

60 mths Replace if bent. Replacement detailed in section .

Oil change in gearboxes, axes 1,2, 3 and 4

40,000 h Lubricated for life. Maintenance free units.


3 Maintenance

3.3.1. Change of oil in wrist unit IRB 2400/10/16 /L

3.3 Changing activites


Location of filling cover on wrist unit .

The gearboxes for axes 1, 2, 3 and 4 are lubricated for life with oil which allows for 40 000

hours in operation. Oil in gearboxes 5 and 6 must be changed at the intervals specified on the

maintenance table.

The oil is checked and changed as described in this chapter.

xx0300000069

Required equipment

Draining the gearbox (IRB 2400/10, /16)

The procedure below details how to drain the oil from the wrist unit.

A Oil plugg

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

Equipment Spare part no.

Art. no. Note

Standard toolkit The contents are defined in section Standard toolkit in the Product manual, reference information!

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.


3 Maintenance


WARNING!

Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure

that protective gear like goggles and gloves are always worn during this activity.

Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there

may be pressure present in the gearbox, causing oil to spray from the opening!


1. Run the upper arm to a horizontal position and turn axis 4 to the calibration position.

xx0300000120

2. Remove the oil plugs in the wristNOTE! loosen the air plug for better draining.

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

xx0300000121

4. Then turn axis 4 another 90°

5. Let the remaining oil run out through the hole on the tilt housing


3 Maintenance


New oil is refilled as follows (IRB 2400/10, 16, L)

The procedure below details how to refill the oil in the wrist unit.

NOTE!

The specified amount of oil is based on the total volume of the gearbox. When changing the

oil, the amount of refilled oil may differ from the specified amount, depending on how much

oil has previously been drained from the gearbox.

WARNING!

When filling gearbox oil, do not mix different types of oil unless specified in the instruction.

Always use the type of oil specified by the manufacturer!


1. Run the upper arm to a horizontal position and turn axis 4 to the calibration position.

2. Fill oil in the hole located on the tilt housing (axis 5) until the oil reaches up to the hole located on the side of the wrist

3. Note! If the robot is mounted in suspension, the wrist should be turned 180°

4. Put the oil plugs back in the wrist


3 Maintenance

3.3.2. Change the backup battery


Location of SMB back up unit

The figure below shows the location of all the SMB back up unit to be inspected.

The battery to be replaced is located in the base (see Figure). The robot is delivered with a

rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4. The battery

must never be just thrown away; it must always be handled as hazardous waste.

xx0300000067

Required equipment

Measuring

The procedure below details how to measur the SMB power backup unit

A SMB backup battery

B SMB backup battery connection cable

Equipment Art. no. Note





3 Maintenance


WARNING!

Please observe the following before commencing any repair work on the manipulator:

• Motors and gears are HOT after running the robot! Touching the motors and gears may

result in burns!

• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

• Take any necessary measures to ensure that the manipulator does not collapse as parts

are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

NOTE!

Always make sure the cable and hose package is secured with the straps delivered with the

kit. These are specially designed not do damage the cables or hoses.

CAUTION!

The cable packs are sensitive to mechanical damage! They must be handled with care,

especially the connectors, in order to avoid damaging them!

Alternative Battery

Alternative Battery As an alternative to the Ni-Cd battery a lithium battery of primary type

can be installed. The lithium battery needs no charging and has for that reason a blocking

diode which prevents charging from the serial measurement board.

The benefit with a lithium 10.8 V battery is the lifetime, which can be up to 5 years in service,

compare with the Ni-Cd battery’s max life time of 3 years in service.

Two lithium batteries exists:

A 3-cell battery art. No. 3HAB 9999-1

A 6-cell battery art. No. 3HAB 9999-2

The life time of the lithium battery depends on how frequently the user switches off the

power.


1. Remov the front cover of the robot fot. Described in section Removal of SMB related equipment on page 123

2. Set the robot to the MOTORS OFF operating mode. (This means that it will not have to be coarse-calibrated after the battery change.)

3. Loosen the battery terminals from the serial measuring board and cut the clasp that keep the battery unit in place.

4. Install a new battery with a clasp and connect the terminals to the serial measuring board.

5. The battery takes 36 hours to recharge; the mains supply must be switched on during this time and there must not be any power interrupts.

6. Mount the front cover of the robot fot Described in sectionReassemble of SMB related equipment on page 127


3 Maintenance


The estimated max life time in years for the different lithium batteries and the recommended

exchange interval is shown below

User type:Exchange 3- cell:

Exchange 6- cell:

Vacation (4 weeks) power off every 5 years every 5 years*

Weekend power off + user type 1 every 2 years every 4 years

Weekend power off + user type 1 and 2 every year every 2 years

* Because of material ageing the maximum life time in service is 5 years.

Min Max

Ni-Cd 7.0 V 8.7 V

Lithium 7.0 V -


3 Maintenance



4 Repair

4.1. Introduction

4 Repair

4.1. Introduction

Structure of this chapter

This chapter details all repair activities recommended for the robot and any external units of

the robot.

It is made up of separate units, each detailing a specific repair activity. Each unit contains all

information required to perform the activity, e.g. spare parts numbers, required special tools

and materials.

The units are gathered in different sections, divided according to the component location on

the robot.

Required equipment

All equipment required to perform a specific repair activity is listed together with the current

procedure.

The equipment is also gathered in different lists in the Product manual, reference information.

Safety information

Before any service work is commenced, it is extremely important that all safety information

is observed!

There are general safety aspects that must be read through, as well as more specific safety

information that describe danger and safety risks when performing specific steps in a

procedure. Make sure to read through the chapter Safety on page 13 before commencing any

service work.


4 Repair

4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General

After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil

must be tested. This is done in a leak-down test.

Required equipment

Procedure

Equipment, etc. Art. no. Note

Leakdown tester 3HAC 0207-1

Leak detection spray -


1. Finish the refitting procedure of the motor or gear in question.

2. Remove the topmost oil plug on the gear in question, and replace it with the leakdown tester .

Adapters may be required, which are included in the leakdown tester kit.

Art. no. is specified above!

3. Apply compressed air, and raise the pressure with the knob until the correct value is shown on the manometer.

Recommended value: 0.2 - 0.25 bar (20 - 25 kPa)

4. Disconnect the compressed air supply.

5. Wait for approx. 8-10 minutes. No pressure loss must be detected.

If the compressed air is significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal.

6. Was any pressure drop evident?

Localize the leak as detailed below.

Remove the leakdown tester, and refit the oil plug.

The test is complete.

7. Spray suspected leak areas with leak detection spray .

Bubbles indicate a leak.

Art. no. is specified above!

8. When the leak has been localized: take the necessary measures to correct the leak.


4 Repair

4.2.2. Mounting instructions for bearings

4.2.2. Mounting instructions for bearings

General

This section details how to mount and grease different types of bearings on the manipulator.

Equipment

Assembly of all bearings

Follow the instructions below when mounting a bearing on the manipulator.

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

2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and

other contamination. Cast components must be free from foundry sand.

3. Bearing rings, inner rings and roller elements must under no circumstances be subjected

to direct impact. Furthermore, the roller elements must not be exposed to any stresses

during the assembly work.

Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings, when mounting a tapered

bearing on the manipulator.

In addition to those instructions, the procedure below must be carried out to enable the roller

elements to adjust to the correct position against the race flange.

1. 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.

2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the

bearing.

Greasing of bearings

The bearings must be greased after assembly, according to instructions below:

• The bearings must not be completely filled with grease. However, if space is available

beside the bearing fitting, the bearing may be totally filled with grease when mounted,

as excessive grease will be pressed out from the bearing when the robot is started.

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

• Ensure that grease is handled and stored properly, to avoid contamination.

Grease the different types of bearings as detailed below:

• 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.


Grease 3HAB 3537-1 Used to grease the bearings, if not specified otherwise.


4 Repair

4.2.3. Mounting instructions for seals


General

This sections details how to mount different types of seals to the manipulator.

Equipment

Rotating seals

The procedure below details 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.


Grease 3HAB 3537-1 Used to lubricate the seals.

Step Action Note

1. 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).

2. Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage.

3. Lubricate the seal with grease just before fitting. (Not too early as there is a risk of dirt and foreign particles adhering to the seal.)

Fill the space between the dust tongue and sealing lip to 2/3 with grease. The rubber coated external diameter must also be greased, unless otherwise specified.

Art. no. is specified in Equipment on page 74.

4. Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in leakage.


4 Repair


Flange seals and static seals

The procedure below details how to fit flange seals and static seals.

O-rings

The procedure below details how to fit o-rings.

Step Action Note

1. Check the flange surfaces. They must be even and free from pores.

It is easy to check flatness using a gauge on the fastened joint (without sealing compund).

If the flange surfaces are defective, the parts may not be used beacuse leakage could occur.

2. Clean the surfaces properly and in accordance with ABB ROBOTICS PRODUCTS recommendations.

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

4. Tighten the screws evenly when fastening the flange joint.

Step Action Note

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

2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings may not be used.

3. Check the o-ring grooves.

The grooves must be geometrically correct and free from pores and contamination.

Defective o-rings may not be used.

4. Lubricate the o-ring with grease.

5. Tighten the screws evenly when assembling.


4 Repair

4.3.1. Removal of cable harness

4.3 Complete robot


Location of Connections in harness

The cable harness is located throughout the manipulator as shown in the figure below.

xx0200000396

A Connector at manipulator base, R1.MP, R1.SMB and R1.C/CS

a1 Electrical connectors rear of the cover plate at the manipulator base , R1.MP1-3, R1.MP4-6, R1.CS, R1.CP, R1.H1, R2.BU, R2.BU1-3, R2.BU4-6,

a2 Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G (bat), R2.FB1-3 and R2.FB4-6

B Connectors at motor 2, R3.MP2 and R3.FB2

C Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2

D Connectors at motor 1, R3.MP1, R3.FB1

E Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4

e Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4

F Connectors at motor 5, R3.MP5 and R3.FB5

G Connectors at motor 6, R3.MP6 and R3.FB6

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

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


4 Repair


Required equipment

Removal, cable harness, axes 1-3

The procedure below details how to remove the cable harness, axes 1-3.

Equipment, etc. Spare part no.

Art. no. Note

Circuit Diagram See chapter Circuit diagram in the Product manual, reference information.





4 Repair


WARNING!



result in burns!




CAUTION!




1. In order to facilitate refitting of the cable harness, run the manipulator to the specified position:

• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °

• Axis 6: no significance

Axes 2 and 3 may be tilted slightly to improve access.

2. Remove the rear cover plate (A) on the manipulator by unscrewing its attachment screws (B).

xx0200000399

3. Disconnect connectors R1.MP1-3 and R2.BU1-3.

4. Disconnect all the earth cables on the R1.M1-3 cable from the back of the cover.


4 Repair


5. Loosen the nuts (D) holding the SMB-unit slightly, then remove it carefully from the bracket.

The cable (A) between the battery (B) and the SMB-unit (C) may stay connected, in order to avoid recalibration of the robot. Be careful not to let the weight of the SMB-unit strain the cable!

In order to remove the SMB-unit completely, the connector R2.G must be disconnected! This causes a necessary recalibration of the robot! Described in Removal of SMB related equipment on page 123.

xx0200000398

6. Disconnect connector R2.FB 1-3 from the connection R2.SMB1-4 (C) on the SMB-unit .

xx0200000400

7. Unscrew the four screws securing the cable gland.

This releases the cable harness from the frame.

8. Remove the adapter plate from the harness by removing its two attachment screws.

xx0200000404

Note! Different manipulator versions are fitted with different plate versions. Make sure the correct one is used to avoid cable failure.

9. Remove the upper bracket securing the cables to the arm house by unscrewing its two attachment screws.

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

10. Remove the back cover of the motors 1-3

Illustrated in (C) figure below.



4 Repair


Removal, cable harness, axes 4-6

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

xx0200000396

11. Disconnect all connectors at motor 1, 2 and motor 3,R3.Mp1-3 (A) and R3.FB1-3 (B)

xx0200000401

12. Remove the 3 screws holding the motor case on motor 1-3

13. Gently pull the cable harness out.







4 Repair


WARNING!



result in burns!














• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °



2. Remove the rear cover plate (A) on the manipulator by unscrewing its attachment screws (B).

xx0200000399

3. Disconnect connectors R1.MP4-6 and R2.BU4-6.

4. Disconnect all the earth cables on the R1.M4-6 cable from the back of the cover.

xx0200000403


4 Repair


5. Loosen the nuts (D) holding the SMB-unit slightly, then remove it carefully from the bracket.

The cable (A) between the battery (B) and the SMB-unit (C) may stay connected, in order to avoid recalibration of the robot. Be careful not to let the weight of the SMB-unit strain the cable!

In order to remove the SMB-unit completely, the connector R2.G must be disconnected! This causes a necessary recalibration of the robot! Described inReassemble of SMB related equipment on page 127.

xx0200000398

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

xx0200000400

7. Unscrew the four screws securing the cable gland.

This releases the cable harness from the frame.

8. Remove the adapter plate from the harness by removing its two attachment screws (A).

xx0200000404




4 Repair


9. Remove the upper bracket securing the cables to the arm house by unscrewing its two attachment screws (C).

Cut the strip clamp (B)

xx0200000405

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

11. Disconnect all connectors at motor 4, 5 and motor 6,R3.Mp4-6 and R3.FB4-6

A- R3.mp5

B- R3.mp6

C- R3.mp4

D- R3.fb5

E- R3.fb6

F- R3.fb4

xx0200000406

12. Remove all screws holding the motor case on motor 4-6

13. Gently pull the cable harness out.



4 Repair

4.3.2. Refitting of cable harness


Location of cable harness

The cable harness is located throughout the manipulator as shown in the figure below.

Location of Connections in harness

xx0200000396














4 Repair


Refitting, cable harness, axes 1-3

The procedure below details how to refit the cable harness, axes 1-3.


Art. no. Note

Cable unit, axes 1-3 3HAC 4791-1

Cable unit, axes 4-6 3HAC 8865-1

Cable unit, axes 4-6 Opt 043

3HAC 8520-1 Option 043

Motor gasket for motor 1-3 3HAC 4419-1

Motor gasket for motor 4-6 3HAB 4429-1

Sealing 3HAB 5922-1

Loctite 574 1234 0011-116 Flange sealing

Cable straps 2166 2055-3 L=208mm






4 Repair


WARNING!



result in burns!




CAUTION!





• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °



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

3. Mount the motor case on motor 1-3 using the 3 screws

Note! Always mount a new gasket art no. 3HAC 4419-1

4. Reconnect all connectors at motor 1, 2 and 3. R3.Mp 1-3 (A) and R3.FB 1-3 (B)

xx0200000401

5. Mount the back cover of the motors 1-3 Use the 5 Torx screw fitted in the holes (C) in figure above.

6. Mount the upper bracket securing the cables to the arm house, using the two attachment screws.


4 Repair


7. Mount the adapter plate to the harness by using its two attachment screws (A).

xx0200000404


8. Mount all the screws securing the cable gland.

This attaches the cable harness to the frame.

Cables

1. A- Power

2. B- Power

3. C- Power

4. D- Customer

5. E- Signal

6. F- Signal

xx0200000402

Note! Make sure that each cable is mounted in the same position as the old ones, otherwise the conduit entry will not be watertight, use 6 cable straps no. 2166 2055-3

Note! Always use a new sealing no. 3HAB 5922-1 and combine it with a flange sealing type Loctite 574 no. 1234 0011-116 for best result.



4 Repair


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

xx0200000400

10. Mount the SMB-unit to the bracket with the nuts (D), be careful not to let the weight of the SMB-unit strain the cable! (A). Described in Reassemble of SMB related equipment on page 127

xx0200000398

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

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

xx0200000403

12. Connect connectors R1.MP1-3 and R2.BU1-3.

13. Mount the rear cover plate (A) on the manipulator with its attachment screws (B).

xx0200000399



4 Repair


Refitting, cable harness, axes 4-6

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

WARNING!



result in burns!




CAUTION!





• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °



2. Gently pull the down the cable harness through the center of lower robot arm and through the hole of axis 1.

3. Mount the motor case on motor 4-6 using the 9 torx screws

Note! Always mount a new gasket art no. 3HAB 4429-1


4 Repair


4. Reconnect all connectors at motor 4, 5 and 6. R3.Mp 4-6 (A) and R3.FB 1-3 (B)

A- R3.mp5

B- R3.mp6

C- R3.mp4

D- R3.fb5

E- R3.fb6

F- R3.fb4

xx0200000406

xx0300000063

xx0300000062



4 Repair


5. Mount the back cover of the motors 4-6

6. Mount the upper bracket securing the cables to the arm house, using the two attachment screws.

7. Mount the adapter plate to the harness by using its two attachment screws (A).

xx0200000404


8. Mount all the screws securing the cable gland.

This attaches the cable harness to the frame.

Cables

1. A- Power

2. B- Power

3. C- Power

4. D- Customer

5. E- Signal

6. F- Signal

xx0200000402

Note! Make sure that each cable is mounted at the same position as the old ones, otherwise the conduit entry will not be watertight.

Note! Always use a new sealing no. 3HAB 5922-1 and combine it with a flange sealing type Loctite 574 no. 1234 0011-116 for best result.



4 Repair


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

xx0200000400

10. Mount the SMB-unit to the bracket with the nuts (D), be careful not to let the weight of the SMB-unit strain the battery cable! (A). Described inReassemble of SMB related equipment on page 127

xx0200000398

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

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

xx0200000403

12. Connect connectors R1.MP4-6 and R2.BU4-6.

13. Mount the rear cover plate (A) on the manipulator with its attachment screws (B).

xx0200000399



4 Repair

4.4.1. Removal of wrist IRB 2400/10/16.

4.4 Upper arm


Location of wrist

The wrist is defined as the manipulators axis 5 and 6, This is shown in pos (A) in the figure

below.

xx0200000409

A Wrist

B Upper arm

C Lower arm

D Frame

E Fot


4 Repair


Required equipment

Location

The procedure below details how to remove the wrist from the robot upper arm.

xx0300000104

The wrist, which includes axes 5 and 6, is a complete unit comprising drive units and

gearboxes. It is a replacement unit of complex design and should not normally be 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 repair work on

the wrist.


Art. no.

Note

Lifting device, manipulator

Special toolkit




A Screws

B Oil-plug

C Wrist


4 Repair


WARNING!



result in burns!




CAUTION!




1. Remove the oil plug on the wrist and drain it from all the oil.

Shown in figure in section Location of wrist on page 93

2. Undo screws and remove the wrist. Shown in figure in section Location of wrist on page 93


4 Repair

4.4.2. Refitting of wrist IRB 2400/10/16


Location of wrist

The wrist is defined as the manipulators axis 5 and 6. This is shown in pos (A) in the figure

below.

xx0200000409

Required equipment

A Wrist

B Upper arm

C Lower arm

D Frame

E Foot


Art. no.

Note


Special toolkit

Grease 3HAB 3537-1 Shell Alvania WR2


4 Repair


Reassemble the new wrist



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.

xx0300000104

WARNING!



result in burns!




NOTE!

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is

used!





Art. no.

Note

A Screws

B Oil-plug

C Wrist


4 Repair



1. Clean the surface of the tubular shaft.

2. Grease the O-ring with grease Shell Alvania WR2, ABB’s art. No, 3HAB 3537-1, to be sure that the O-ring between the upper arm tubular and the wrist do not get displaced, and mount it in its position on the upper arm tubular.

Shown in Reassemble the new wrist on page 97

3. Mount two M8 guide pins (A) (length = 70 mm) diagonally on the wrist. Carefully push the wrist against the tubular. When the gears are meeting each other, they may need to be rotated to mesh properly.

xx0200000424

4. Fix the wrist with two screws and two washers. Dismantle the M8 guide pins. Mount the other two screws and washers.

5. Release the brakes on axes 5 and 6 (one at the time) and mount tool 3HAB 7887-1 at the rear of the motor.

Manually releasing the brakes on page 47

6. Push the wrist, as shown in Figure, to locate the smallest play in the same way as for adjustment of play when changing motors for axes 5 and 6, see the section Refitting of motor, axis 4-6 on page 162

xx0200000425

A- Gears on drive shaft unit, axis 5-6

B- Gears on the wrist

7. Tighten screws (A) with washer to a torque of 17 Nm

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

9. Fill with oil. See the sectionChange of oil in wrist unit IRB 2400/10/16 /L on page 64

10. Calibrate the robot. Calibration is detailed in separate calibration manuals.

Art. no. for the manuals are specified in section Document references in the Product manual, reference information.


4 Repair

4.4.3. Removal of wrist IRB 2400L


Location of wrist


below.

x0300000409

Required equipment

A Wrist

B Upper arm

C Lower arm

D Frame

E Foot


Art. no. Note


Special toolkit


4 Repair


Location

The procedure below details how to remove the wrist from the robot upper arm.



on-site. Instead it should be sent to ABB for service etc.

ABB recommends its customers to carry out only the following servicing and repair work on

the wrist.

WARNING!





WARNING!



result in burns!








Art. no. Note


4 Repair



1. Remove the oil plug on the wrist and drain it from all the oil.

x0300000104

• A : Screw

• B : Oil plug (air inlet)

• Wrist unit

2. Undo screws and remove the wrist


4 Repair

4.4.4. Refitting of wrist IRB 2400L.


Location of wrist


below.

x0200000409

Required equipment

A Wrist

B Upper arm

C Lower arm

D Frame

E Foot


Art. no. Note





4 Repair


Location

Grease



Art. no. Note


1. Clean the surface of the tubular shaft

2. Apply Loctite 574 all around.

3. Mount the wrist, tighten screws to a torque of 8.3 Nm 10±%

4. Screw the clamping sleeves together using screws to a torque of 5.7 Nm

5. Replace the plugs

6. Mount the cover at the motor side of axis 5-6.

7. Calibrate the robot! Calibration is detailed in separate calibration manuals.



4 Repair

4.4.5. Removal of complete upper arm


Location

The upper arm is located on top of the manipulator as shown in (A) and (B) the figure below.

The complete upper arm includes the wrist unit.

xx0200000409

Required equipment

A Wrist axis 5-6

B Upper arm axis 4-3

C Lower arm axis 2

D Frame axis 1

E Robot foot


Art. no. Note/Illustration

Lifting device, upper arm

Special tool 3HAB 9009-1

Lifting tool (chain) To be used together with lifting eye, M12 and lifting device, upper arm.


4 Repair


Tie Rod attachment

xx0200000436

Removal

The procedure below details how to remove the complete upper arm.

WARNING!



result in burns!




CAUTION!







Art. no. Note/Illustration

A Cover

B KM nuts

C Screw


4 Repair



1. Dismount the tie rod as described in chapter Removal of the tie rod on page 117

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

Detailed in Removal of motor, axis 4-6;IRB 2400L on page 159

3. Disconnect the connection box from the motors.

4. Remove the covers (Left + Right) Detailed in Tie Rod attachment on page 105

5. Undo the KM nuts (Left + Right). Use sleeve 6369 901-480

Detailed in Tie Rod attachment on page 105

6. Remove screws (Left + Right) Detailed in Tie Rod attachment on page 105

7. Mount the lifting device to the upper arm, and lift enough for the strap to stretch without lifting the robot.

xx0200000435

Lifting without lifting tool!

8. Pull out the shaft. Use tool 3HAB 9009-1. Mark the shafts (left, right).


4 Repair

4.4.6. Reassemble of complete upper arm


Location

The upper arm is located on top of the manipulator as shown in (A) and (B) the figure below.

The complete upper arm includes the wrist unit.

xx0200000409

Required equipment

A Wrist axis 5-6

B Upper arm axis 4-3

C Lower arm axis 2

D Frame axis 1

E Robot foot


Art. no.

Note/Illustration

Lifting device, upper arm

Special tool 3HAB 9009-1

Lifting tool Lifting strap


4 Repair


Tie Rod attachment

xx0200000436

Reassemble

The procedure below details how to reinstall the complete upper arm.





Art. no.

Note/Illustration

A Cover

B KM nuts

C Screw


4 Repair


WARNING!



result in burns!




WARNING!

Ensure that

• - the area around the manipulator is clear as the machine can swing round as it leaves

the pallet!

• - the trolley has free movement while lifting. If the trolley gets stuck, the manipulator

is likely to fall off and can cause personal injury and damage to the manipulator!


1. Mount sealings in the upper arm

2. Mount the inner ring of the bearings on shafts. Use tool No. 3HAB 6464-1.

3. Raise the upper arm into the assembly position.

4. Install shaft spindles (both sides).

5. Insert screws and tighten. 90 Nm

6. The following procedure must be performed within 10 minutes, before the Loctite starts to harden.

• Apply Loctite 243 on the KM-nuts (B)

• Tighten the KM-nut on the left side first (robot seen from behind) so that the bearing comes against the collar.

• Unscrew the KM-nut and then tighten with a torque of 35 Nm

• Tighten the KM-nut on the right side, move the 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

• Mount the covers (A)

• Push in a strap from the other under the sealing, so that the air can go out

Illustrated in section Tie Rod attachment on page 108

7. Mount the sync. plate for axis 3.

8. Reconnect the connection boxes and the cabling.

9. Calibrate the robot as specified in this chapter, Calibration in the installation manual


4 Repair

4.5.1. Removal of complete lower arm

4.5 Lower arm


Location of lower arm

The lower arm is located as shown (C) in the figure below.

A more detailed view of the component and its position may be found in chapter Foldouts in

the Product manual, reference information.

xx0200000409

A Wrist

B Upper arm

C Lower arm

D Frame

E Robot foot


4 Repair


Required equipment

Lifting off the lower arm

xx0200000439

Removal of complete lower arm

The procedure below details how to remove the complete lower arm.

Equipment, etc. Spare part no. Art. no. Note

Hoisting equipment





4 Repair


WARNING!


• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result

from touching them!

• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!

• When replacing motors/reducers, make sure that those parts of the robot which could

move unexpectedly are mechanically blocked as specified in the individual

procedures.

NOTE!

• Before removing, clean the work area and the components to be removed.

• Place the removed components in a clean container.


1. Remove the upper arm.

xx0200000435

Detailed in Removal of complete upper arm on page 104.

2. Attach the crane to the lower arm Shown in the figure in section Lifting off the lower arm on page 111

3. Remove the tie rod. Detailed in Removal of the tie rod on page 117.

4. Remove the parallel arm Detailed in Removal of the parallel arm on page 135

5. Disconnect and remove the cables from inside the lower arm.

Release any cable attachments.

Detailed in Removal of cable harness on page 76.


4 Repair


6. Loosen all screws (A)

xx0200000440

7. Take off the lower arm Shown in the figure in section Lifting off the lower arm on page 111



4 Repair

4.5.2. Refitting of complete lower arm


Location of lower arm

The lower arm (C) is located as shown in the figure below.



xx0200000409

A Wrist

B Upper arm

C Lower arm

D Frame

E Robot foot


4 Repair


Required equipment

Reassemble of lower arm

xx0200000441

Refitting, lower arm

The procedure below details how to refit the complete lower arm.


Art. no. Note

Bearing Grease 3HAB 3537-1 For lubricating shaft hole





4 Repair


WARNING!



result in burns!




WARNING!

Ensure that

• - the area around the manipulator is clear as the machine can swing round as it leaves

the pallet!

• - the trolley has free movement while lifting. If the trolley gets stuck, the manipulator

is likely to fall off and can cause personal injury and damage to the manipulator!


1. Transfer the damping element and calibration marking to the new lower arm.

Only if the arm is replaced with a new.

2. Lift the lower arm into position. Shown in illustration Reassemble of lower arm on page 115

3. Fix the lower arm to gearbox 2 using screws and tighten.

68 Nm

4. Assemble the parallel arm Detailed in chapterReassemble of the parallel arm on page 137

5. Fix the parallel arm to gearbox 3 using screws and tighten.

68 Nm

6. Replace the upper arm Detailed in chapterReassemble of complete upper arm on page 107

7. Replace the cabling Described in chapter Refitting of cable harness on page 84

8. Recalibrate the robot! Calibration is detailed in separate calibration manuals.



4 Repair

4.5.3. Removal of the tie rod


Location of tie rod

The tie rod is located as shown in the figure below.



xx0200000442

Required equipment

A Tie rod

B Parallel arm


Art. no. Note





4 Repair


Tie rod

xx0200000443

Removal of tie rod

The procedure below details how to remove the tie rod.

A Bearing Sealing

B Back up ring

C Screw, hex. socket head cap

D Locking Washer

E Bearing

Upper connection IRB 2400 5 kg

F Bearing Sealing

G Bearing

H Bearing Sealing

I Screw


4 Repair


WARNING!



result in burns!




CAUTION!




1. Remove screw (A) upper. Shown in Illustration Tie rod on page 118

2. Remove screw (A) lower. Shown in Illustration Tie rod on page 118

3. Remove Locking Washer (B) Shown in Illustration Tie rod on page 118

4. Insert a screw in the center, to be used as support.

5. Use a crane to secure the upper arm. Shown in figure in section Location of tie rod on page 117

6. Use a puller to pull out the tie rod

7. Change the bearings (D) and seals Shown in Illustration Tie rod on page 118


4 Repair

4.5.4. Reassemble of the tie rod


Location of tie rod

The tie rod is located as shown in the figure below.



xx0200000444

Required equipment

A Tie rod

B Parallel arm


Art. no. Note

Loctite 243

Grease





4 Repair


Tie rod

xx0200000443

Reassemble

The procedure below details how to reassemble the tie rod.

NOTE!

Please observe the following when refitting components:

• Carefully clean the connecting surfaces.

• Ensure that there are no damaged surfaces or other parts that need rectifying or

replacing.

• Replace all gaskets.

A Bearing Sealing

B Back up ring

C Screw, hex. socket head cap

D Locking Washer

E Bearing

Upper connection IRB 2400 5 kg

F Bearing Sealing

G Bearing

H Bearing Sealing

I Screw


4 Repair



1. Be sure to secure the upper arm. Use a crane!

Shown in figure section Location of tie rod on page 120

2. Fit the new bearings in the tie rod (D). Shown in section Tie rod on page 121

Use special tool 3HAB 6324-1.

3. Fit a new shaft sealing (E). Shown in section Tie rod on page 121

Use special tool 3HAB 6324-1.

4. Refit the tie rod.. Use special tool 3HAB 6331-1.

5. Refit the back up ring Shown in section Tie rod on page 121

6. Refit the Locking Washer Shown in section Tie rod on page 121

7. Refit all screws. Shown in section Tie rod on page 121

Secure with Loctite 243


4 Repair

4.6.1. Removal of SMB related equipment

4.6 Frame and base


Location of SMB board

The SMB related equipment (SMB = serial measurement board) is located on the left hand

side of the frame as shown in the figure below.



Note that the manipulator is shown with the SMB cover already removed!

xx0200000451

A Cable to back up battery

B Back up battery

C Serial Measurement Board

D Lock Nuts


4 Repair


Required equipment

Cover robot foot

xx0200000399

Removal, cover on robot foot

The procedure below details how to remove the cover on the robot foot

Equipment, etc. Spare part. no.

Art. no. Note

Gasket 3HAB 5537-1

SMB- unit 3HAB 8413-01

Battery unit 4944 026-4





A Cover plate

B Screw


4 Repair


WARNING!



result in burns!




Removal, battery

The procedure below details how to remove the SMB battery.


1. Remove the Screws to the cover Shown in the illustration Cover robot foot on page 124

2. Remove the cover gasket art. no. 3HAB 5537-1 NOTE! Always change every removed gasket .


1. Remove the SMB battery cover by unscrewing its attachment screws .

Shown in figure in section Location of SMB board on page 123

2. Disconnect the battery from the cable, battery/SMB board .

3. Remove the SMB battery.


4 Repair


SMB unit

xx0200000452

Removal, SMB unit

The procedure below details how to remove the SMB unit.

NOTE!



A R2.SMB1-2 (External axis)

B R2.SMB1-3

C R2.SMB4-6

D Back up battery (R2.G)

E R2.SMB (Motor Brake)


1. Remove the SMB battery. Detailed above in Removal, battery on page 125.

2. Remove the SMB cover by unscrewing its attachment screws.

Pull the battery cable through the hole in the SMB cover.

3. Remove the two locknuts and washers from the pins securing the board.

Shown in illustration SMB unit on page 126

4. Gently disconnect the connectors from the SMB unit when pulling the board out.

Connectors R1.SMB1-3, R1.SMB4-6 and R2.SMB

5. Also disconnect the battery cable from the SMB unit.


4 Repair

4.6.2. Reassemble of SMB related equipment


Location of SMB board

The SMB related equipment (SMB = serial measurement board) is located on the left hand

side of the frame as shown in the figure below.



Note that the manipulator is shown with the SMB cover already removed!

xx0200000451

A Cable to back up battery

B Back up battery

C Serial Measurement Board

D Lock Nuts


4 Repair


Required equipment

SMB unit

xx0200000452

Equipment, etc. Spare part. no.

Art. no. Note

Gasket 3HAB 5537-1

SMB- unit 3HAB 8413-01

Battery unit 4944 026-4





A R1.SMB1-2

B R1.SMB1-3

C R1.SMB4-6

D R2.G

E R2:SMB


4 Repair


Reassemble, SMB unit

The procedure below details how to reassemble the SMB unit.

Reassemble of, battery

The procedure below details how to reassemble the SMB battery.

Cover robot foot

xx0200000399

Reassemble of, cover on robot foot

The procedure below details how to reassemble the cover on the robot foot


1. Gently connect the connectors to the SMB unit when pushing the board in.

Connectors R1.SMB1-3 (B), R1.SMB4-6 (C) and R2.SMB (E) Shown in illustration in section SMB unit on page 128

2. Reassemble the SMB cover using the attachment lock nuts.

Pull the battery cable through the hole in the SMB cover.


3. Reassemble the two locknuts and washers to the pins securing the board.



1. Reassemble the SMB battery .

2. Connect the battery to the cable, battery/SMB board .

Pos (D) R2.G Shown in illustration in section SMB unit on page 128

3. Reassemble the SMB battery cover using its attachment screws.


A Cover

B Screws


4 Repair



1. Reassemble the cover gasket . NOTE! Always change every removed gasket .

Art.no. 3HAB 5537-1

2. Reassemble the Screws holding the cover Shown in the illustration Cover robot foot


4 Repair

4.6.3. Removal of brake release unit


Location and description of brake release unit

The push-button unit is located on the flange plate on the base and is used to quickly and

safely release the axis brakes manually, when doing various types of work on and around the

robot. It is also possible to move the arms of the robot manually, when this is necessary.

The push-button unit (A) is equipped with six buttons for controlling the axis brakes. The

buttons are numbered with the axes numbers. The unit is located underneath a rubber cover

in the cover. The brakes are of electromechanical type and are released when voltage is

applied. To release the brake on a particular axis, push the appropriate button and keep it

depressed. The brake will function again as soon as the button is released.

xx0200000459

Required equipment

Removal of brake release unit

The procedure below details how to remove the brake release circuit, located at the rear of the

base.

A Brake release


Art. no. Note





4 Repair


WARNING!



from touching them!




procedures.

NOTE!



CAUTION!

If the manipulator normally works in an inverted position, it must be removed from this

position and placed on the floor before the work detailed in this instruction may be carried

out !


1. Remove the cover at the rear of the base.

2. Unscrew the six attachment screws to the brake release circuit on the outside of the base.

Shown in section Location and description of brake release unit on page 131

3. Disconnect the cable from the brake release circuit and remove the circuit from the base.


4 Repair

4.6.4. Reassemble of brake release unit


Location and description of brake release unit

The push-button unit is located on the flange plate on the base and is used to quickly and

safely release the axis brakes manually, when doing various types of work on and around the

robot. It is then also possible to move the arms of the robot manually, when this is necessary.

The push-button unit (A) is equipped with six buttons for controlling the axis brakes. The

buttons are numbered with the axes numbers. The unit is located underneath a rubber cover

in the cover. The brakes are of electromechanical type and are released when voltage is

applied. To release the brake on a particular axis, push the appropriate button and keep it

depressed. The brake will function again as soon as the button is released.

xx0200000463

Required equipment

Removal of brake release unit

The procedure below details how to reassemble the brake release circuit, located at the rear

of the base.

A Brake release unit, axis 1-6


Art. no.

Note





4 Repair


NOTE!

The robot must not be in the STANDBY MODE! This applies for all types of cabling work.

NOTE!




replacing.


WARNING!



from touching them!




procedures.


1. Reconnect the cable to the brake release circuit and reassemble the circuit to the base.

Shown in section Required equipment on page 133

2. Use the six attachment screws to the brake release circuit on the outside of the base.

Shown in section Required equipment on page 133

3. Reassemble the cover at the rear of the base.


4 Repair

4.6.5. Removal of the parallel arm


Location of parallel arm

The parallel arm is located as shown in the figure below.



xx0200000444

Required equipment

Removal parallel arm

The procedure below details how to remove the parallel arm.

A Tie rod

B Parallel arm


Art. no.

Note


Special toolkit




4 Repair


WARNING!



result in burns!





1. Loosen the tie rod Described in chapterRemoval of the tie rod on page 117

2. Remove the parallel arm


4 Repair

4.6.6. Reassemble of the parallel arm


Location of parallel arm

The parallel arm is located as shown in the figure below.



xx0200000444

Required equipment

A Tie rod

B Parallel arm


Art. no. Note

Groove ball bearing 3HAB 3643-12 61822-2RS1

Sealing V-ring 3HAB 5515-1 Acetal (POM)

Bearing grease 3HAB 3537-1 1 g



4 Repair


Assembly

The procedure below details how to assemble the sealing, bearing and how do mount parallel

arm on the robot.

xx0200000450

NOTE!




replacing.


Special toolkit




Art. no. Note

A Parallel arm

B Sealing V- ring

C Groove ball bearing

D Screw (hex.socket head cap )


4 Repair



1. Mount V-ring (B) on the parallel arm (A)

2. Fit a new bearing to the parallel arm. NOTE! Heat up the bearing to 170 C° before mounting it on the parallel arm.

3. Mount the other V-ring (B) on the parallel arm (A)

4. Replace the screws and tighten. Torque of 72 Nm.

5. Mount the tie rod. Described in chapterReassemble of the tie rod on page 120


4 Repair

4.7.1. Removal of motor, axis 1

4.7 Motors


Location of motor axis 1

The motor axis 1 is located on the left hand side of the manipulator as shown in the figure

below:



xx0200000465

A Cover

B Connection box

C Screw + Spring washer

D Motor axis 1

E Position mark


4 Repair


Required equipment

Removal

The procedure below details how to remove motor, axis 1.

WARNING!



result in burns!




CAUTION!




Art. no.

Note






1. Remove the cover of the connection box

Shown in figure in section Location of motor axis 1 on page 140

2. Loosen connectors R3.MP1 and R3.FB1

xx0200000406

• A: R3.MP1

• B: R3.FB1

• C: Connection box

3. Remove the Connection box by unscrewing its three attachment screws and plain washers.


4 Repair


4. Use a marker pen to mark out the position of the motor

Shown in figure in sectionLocation of motor axis 1 on page 140

5. Remove the motor by unscrewing its four attachment screws and plain washers.

6. Remove the motor by gently lifting it straight up.




4 Repair

4.7.2. Refitting of motor, axis 1




below:



xx0200000465

A Cover

B Connection box

C Screws

D Motor axis 1

E Marking

F O-ring


4 Repair


Required equipment

Removal

The procedure below details how to refit motor, axis 1.


Art. no. Note




Gasket 3HAB 3676-1

O-ring 3HAB 3772-1



1. Check that the assembly surfaces are clean and the motor unscratched

2. Mount the O-ring Always mount a new one, see art. no. in section Location of motor axis 1 on page 143

3. Install the motor, by gently lifting it straight on

4. Tighten the four screws Note the position of the motor! use the mark on the motor foot, shown in figure in sectionLocation of motor axis 1 on page 143

2 Nm

5. Refit the Connection box by assemble the three attachment screws and plain washers.

6. Reconnect connectors R3.MP1 and R3.FB1

xx0200000406

• A: R3.MP1

• B: R3.FB1


7. Refit the cover of the connection box Shown in figure in sectionLocation of motor axis 1 on page 143


4 Repair





below:



xx0200000470

A Torx screw

B Cover

C Connection box

D Gasket

E Motor 2

F Screw

G O-ring


4 Repair


Required equipment

Removal, motor axis 2


WARNING!



result in burns!




NOTE!



WARNING!






Art. no.

Note






4 Repair






xx0200000401

• A: R3.MP2

• B: R3.FB2





5. Secure the upper arm before unscrewing any of the motor attachment screws.

xx0300000107


WARNING! The oil in the gear house leaks out when the motor is removed.

7. Remove the motor by gently lifting it straight out.



4 Repair





below:



xx0200000470

A Torx screw

B Cover

C Connection box

D Gasket

E Motor 2

F Screw

G O-ring


4 Repair


Required equipment

Refit motor 2

The procedure below details how to refit motor, axis 2.

NOTE!




replacing.


NOTE!


used!


Art. no. Note




Gasket 3HAB 3676-1

O-ring 3HAB 3772-1


Mounting tool 3HAB 7887-1


1. Check that the assembly surfaces are clean and the motor unscratched.

2. Fit the O-ring. Always fit a new one, see art. no. in section Location of motor axis 2 on page 148

3. Install the motor, by gently lifting it straight on.

4. Tighten the four screws. Note the position of the motor! use the mark on the motor foot, shown in figure in section.Location of motor axis 2 on page 148

2 Nm.

5. Release the brake by applying 24 VDC to terminals 7(+) and 8 in the R3.MP1 connector.


4 Repair


6. Fit the tool at the rear of the motor. See figure below.

Tool No. 3HAB 7887-1 at

7. Turn the motor shaft a couple of turns, with help of the tool.

See figure below.

8. Place the tip of a dial indicator against the scribed mark on the measuring tool.

The tip of the dial indicator must measure on a 50 mm radius from the centre of the motor shaft .

Se figure below.

9. Set the gear play to 0.02 mm, which corresponds to a reading on the dial indicator of 0.13 mm.

xx0200000473

• A: Mount tool No. 3HAB 7887-1

10. Pull gently in one direction. Note the reading. (The gear must not turn.)

See figure above.

11. Then gently knock on the tool in the other direction and note the reading. The difference in reading = gear play. The gear play should be 0.02 mm which corresponds to a reading on the dial indicator of 0.13 mm.

See figure above.

12. Tighten screws <1/8, 1/9>. 23 Nm

13. Fill with oil.

14. Refit the Connection box by assembling the three attachment screws and plain washers.



4 Repair


15. Reconnect connectors R3.MP2 and R3.FB2.

xx0200000401

• A: R3.MP2

• B: R3.FB2


16. Refit the cover of the connection box. Shown in figure in sectionLocation of motor axis 2 on page 148





4 Repair




The motor axis 3 is located on the right hand side of the manipulator as shown in the figure

below:



xx0200000471

A Torxs screw

B Cover

C Connection box

D Gasket

E Motor 2

F Screw

G O-ring


4 Repair


Required equipment

Removal, motor axis 3


WARNING!



result in burns!




NOTE!


used!


Art. no.

Note









xx0200000401

• A: R3.MP3

• B: R3.FB3




4 Repair




5. Secure the upper arm before loosening any of the screws on the motor.

xx0300000107


WARNING! The oil in the gear house leaks out when the motor is removed

7. Remove the motor by gently lifting it straight out.




4 Repair





below:



xx0200000471

A Torx screw

B Cover

C Connection box

D Gasket

E Motor 2

F Screw

G O-ring


4 Repair


Required equipment

Refitt motor 3

The procedure below details how to refitt motor, axis 3.

WARNING!



result in burns!




NOTE!


used!

NOTE!




replacing.



Art. no. Note




Gasket 3HAB 3676-1

O-ring 3HAB 3772-1


Mounting tool 3HAB 7887-1


1. Check that the assembly surfaces are clean and the motor unscratched.

2. Mount the O-ring. Always mount a new one, see art. no. in section Required equipment on page 156

3. Install the motor, by gently lifting it straight on.


4 Repair


4. Tighten the four screws using a torque of 2 Nm.

Note the position of the motor! Use the mark on the motor foot, shown in figure in section.Refitting of motor, axis 1 on page 143

5. Release the brake by applying 24 V d.c. to terminals 7(+) and 8 in the R3.MP3 connector.

6. Mount tool No. 3HAB 7887-1 at the rear of the motor.

See figure below.

7. Turn the motor shaft a couple of turns, with help of the tool.

See figure below.

8. Place the tip of a dial indicator against the scribed mark on the measuring tool.

The tip of the dial indicator must measure on a 50 mm radius from the center of the motor shaft .

Se figure below.

9. Set the gear play to 0.02 mm, which corresponds to a reading on the dial indicator of 0.13 mm.

xx0200000473

• A: Mount tool No. 3HAB 7887-1

10. Pull gently in one direction. Note the reading. (The gear must not turn.)

See figure abowe

11. Then gently knock on the tool in the other direction and note the reading. The difference in reading = gear play. The gear play should be 0.02 mm which corresponds to a reading on the dial indicator of 0.13 mm

See figure abowe

12. Tighten the motor attachment screws. 23 Nm

13. Fill with oil. See the chapter, Section Oil Change in Gearboxes in maintenance manual

14. Refit the Connection box by assembling the three attachment screws and plain washers.



4 Repair


15. Reconnect connectors R3.MP3 and R3.FB3.

xx0200000401

• A: R3.MP3

• B: R3.FB3


16. Refitt the cover of the connection box. Shown in figure in sectionRefitting of motor, axis 1 on page 143





4 Repair

4.7.7. Removal of motor, axis 4-6;IRB 2400L


Location of motor axis 4-6


below:

The motor axis 5-6 is located on the back side of the manipulator as shown in the figure

below:



xx0200000476

Required equipment

A Torx screw

B Cover

C Connection box

D Screw

E Motor 6

F Motor 5

G Motor 4

H Gearbox


Art. no.

ote






4 Repair


Removal, motor axis 5-6 (5 kg)

The procedure below details how to remove motor, axis 4-6.

WARNING!


• - Motors and gears are HOT after running the robot! Burns may result from touching

the motors or gears!

• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

• - Take any necessary measures to ensure that the manipulator does not collapse as

parts are removed, e.g. securing the lower arm with fixtures before removing motor,

axis 2.

NOTE!

Whenever mating motor and gearbox, misalignment of the gears may severely damage them.

Avoid this risk:

• Fit the gearbox.

• Turn the gears of the gearbox to the correct position using the gearbox crank. The part

number is specified in the table above!

• Fit the motor.

NOTE!

• - Before removing, clean the work area and the components to be removed.

• - Place the removed components in a clean container.



Shown in figure in section Location of motor axis 4-6 on page 159

2. Loosen connectors R3.MP5-6 and R3.FB5-6

xx0300000063



4 Repair


Removal, motor axis 4 (5 kg)


4. Use a marker pen to mark out the position of the motors


5. Remove the motor by unscrewing its attachment screws and plain washers.

6. Remove the motors by gently lifting them straight up (horizontal movement).




1. Remove the cover of the connection box.

xx0200000401

• A: R3.MP4

• B: R3.FB4

• C: Case

2. Loosen connectors R3.MP4 and R3.FB4.

Shown in figure above.


4. Use a marker pen to mark out the position of the motors.


WARNING! The gearbox is filled with oil, to avoid oil from leaking when dismounting the motors, drain the oil from the gearbox.

6. Remove the motors by gently lifting them straight up (horizontal movement).


4 Repair

4.7.8. Refitting of motor, axis 4-6




below:

The motor axis 5-6 is located on the back side of the manipulator as shown in the figure

below:



xx0200000476

Required equipment

A Torx screw

B Cover

C Connection box

D Screw

E Motor 6

F Motor 5

G Motor 4

H Gearbox


Art. no. Note

O-ring 3HAB 3772-1 3 pcs

Loctite 243 3HAB 7116-1

Bearing grease 3HAB 3537-1

Mount tool 3HAB 7887-1

Lubricating oil 1171 2016-604



4 Repair


Reassemble of motor axis 4

The procedure below details how to reassemble motor, axis 4.

WARNING!



result in burns!




NOTE!


used!





Art. no. Note



2. Mount a new O-ring on the motor. 3HAB 3772-1

3. Grease the gear with bearing grease 3HAB 3537-1


4 Repair


4. Mount the tool at the rear of the motor.

xx0300000005

• A: Tool no. 3HAB 7887-1

5. The motor’s fixing screws shall be fastened, but do not tighten them, to ensure that the motor will be able to move parallel to the gear when the adjustment is done

6. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connectors

7. Start with a play in all positions and then locate the smallest play by turning the motor shaft 6 turns and thereby find the area with the smallest play within this range. Use swift movements to avoid noticing the magnetic field, which makes the gears stick together.

8. Push or tap the motor in radial direction so that the play becomes minimal within one motor turn, without the gear “chewing”. Do not use force!

9. Tighten the motor attachment screws and secure them with locking fluid.

4.1 Nm

Loctite 243

10. Fill with oil. 30ml

11. Connect the cabling. Described in Refitting of cable harness on page 84.





4 Repair








2. Fit a new O-ring on the motor. 3HAB 3772-1

3. Fit the tool at the rear of the motor. Look at the figure in section Reassemble of motor axis 4 on page 163

Tool no. 3HAB7887-1.

4. The motor’s fixing screws shall be fastened, but do not tighten them, to ensure that the motor will be able to move parallel to the gear when the adjustment is done


6. Locate the smallest play by turning the outgoing shaft for axis 4 in intervals of 90°, one full turn, and thereby find the area where the play for motor 5 becomes smallest. Turn the motor for axis 5 one full turn at a time for a total of 5 turns. Find where the smallest play is within this area. Use swift movements to avoid noticing the magnetic field, which makes the gears stick together.



4.1 Nm

Loctite 243


10. Calibrate the robot Calibration is detailed in separate calibration manuals.




2. Fit an new O-ring on the motor. 3HAB 3772-1


4 Repair


3. Fit the tool at the rear of the motor. Look at the figure in section Reassemble of motor axis 4 on page 163.

Tool no. 3HAB7887-1.

4. The motor’s fixing screws shall be fastened, but do not tighten them, to esure that the motor will be able to move parallel to the gear when the adjustment is done


6. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of 90°, totally one whole turn, and thereby find the area where the play for motor 6 becomes smallest. Turn the motor for axis 5 one full turn at the time, totally 5 turns. Find the smallest play for axis 6 within this area. Turn the motor for axis 6 one full turn at a time for a time for a total of 3 turns. Find the smallest play for axis 6 within this area. Use swift movements to avoid noticing the magnetic field, which makes the gears stick together



4.1 Nm.

Loctite 243

9. Connect the cabling. Described in Refitting of cable harness on page 84

10. Calibrate the robot Calibration is detailed in separate calibration manuals.




4 Repair

4.7.9. Removal of motor, axis 4-6, IRB 2400/10/16



The motor axis 4-6 is located on the back of the manipulator as shown in the figure below:



xx0300000108

Required equipment

Removal, motor axis 4-6 (10/16 kg)

The procedure below details how to remove motor, axis 4-6.

A Torx screw

B Cover

C Connection box

D Screw

E Motor 6

F Motor 5

G Motor 4

H Gearbox


Art. no. Note





4 Repair


WARNING!





WARNING!



result in burns!




NOTE!





Shown in figure in section xx.

2. Loosen connectors R3.MP4-6 and R3.FB4-6

xx0200000406

• A: R3.MP5

• B: R3.MP6

• C: R3.MP4

• D: R3.FB5

• E: R3.FB6

• F: R3.FB4


4. Use a marker pen to mark out the position of the motors


4 Repair



WARNING! The gearbox is filled with oil, to avoid leak when dismounting the motors, drain the oil from the gearbox.

6. Remove the motors by gently lifting them straight out (horizontal movement).



4 Repair

4.7.10. Refitting of motor, axis 4-6 IRB 2400/10/16



The motor axis 4-6 is located on the back of the manipulator as shown in the figure below:



xx0300000108

Required equipment

A Torx screw

B Cover

C Connection box

D Screw

E Motor 6

F Motor 5

G Motor 4

H Gearbox


Art. no. Note

O-ring 3HAB 3772-1

Loctite 243 3HAB 7116-1

Bearing grease 3HAB 3537-1

Mount tool 3HAB 7887-1

Lubricating oil 1171 2016-604



4 Repair






Reused screws may be used, providing they are lubricated as detailed in Screw Joints before fitting.

Circuit Diagram 3HAC 6670-3 See chapter Circuit diagram in the Product manual, reference information.


Art. no. Note




3. Grease the gear with bearing grease 3HAB 3537-1

4. Fit the tool at the rear of the motor.

xx0300000005

Tool no. 3HAB 7887-1

5. The motor’s fixing screws shall be fastened, but do not tighten them, to be sure that the motor will be able to move parallel to the gear when the adjustment is done



4 Repair






7. Start with a play in all positions and then seek up the smallest play by turning the motor shaft 6 turns and thereby find the area with the smallest play within this range. Use swift movements to avoid noticing the magnetic field, which makes the gears stick together.



4.1 Nm.

Loctite 243

10. Fill the gearbox whith the proper quantity of oil

1.5 litres (0.4 US gallon)






3. Mount the tool at the rear of the motor. Tool no. 3HAB7887-1



6. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of 90°, one full turn, and thereby find the area where the play for motor 5 becomes smallest. Turn the motor for axis 5 one full turn at a time for a total of 5 turns. Find where the smallest play is within this area. Use swift movements to avoid noticing the magnetic field, which makes the gears stick together.



4.1 Nm.

Loctite 243



4 Repair



1. Check that the assembly surfaces are clean and the motor unstructured.


3. Fit the tool at the rear of the motor. Tool no. 3HAB 7887-1.



6. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of 90°, one full turn, and thereby find the area where the play for motor 6 becomes smallest. Turn the motor for axis 5 one full turn at the time, totally 5 turns. Find the smallest play for axis 6 within this area. Turn the motor for axis 6 one full turn at a for a total of 3 turns. Find the smallest play for axis 6 within this area. Use swift movements to avoid noticing the magnetic field, which makes the gears stick together



4.1 Nm.

Loctite 243

9. Fill the gearbox with the proper quantity of oil 0.8 litres (0.2 US gallon) total for 5 and 6.





4 Repair

4.8.1. Removal of gearbox, axis 1-3

4.8 Gearboxes


Location of gearbox axis 1-3

The axis 1 gearbox is located between the frame and base as shown in the figure below.

Axis 1 gearbox is of the conventional type, manufactured with high precision, and together

with the gearboxes for axes 2 and 3, forms a complete unit.



The gearbox is not normally serviced or adjusted.

xx0300000007

Required equipment

A M12x50 8.8 hexagon socket head cap screw

B Cover


Art. no.

Note





4 Repair


Removal

The procedure below details how to remove gearbox, axis 1-3.

WARNING!



result in burns!




NOTE!




1. Remove the complete lower arm. Detailed in Removal of complete lower arm on page 110.

2. Remove the motor, axis 1. Detailed inRemoval of motor, axis 1 on page 140.

3. Remove the motor, axis 2. Detailed in Removal of motor, axis 2 on page 145.

4. Remove the motor, axis 3. Detailed in Removal of motor, axis 3 on page 152.

5. Place the remaining parts of the manipulator upside-down on a table or similar surface and remove the bottom plate.

6. Undo all 12, M12 hex. sock. screws


4 Repair

4.8.2. Refitting of gearbox, axis 1-3


Location of gearbox axis 1-3

The axis 1 gearbox is located between the frame and base as shown in the figure below.

Axis 1 gearbox is of the conventional type, manufactured with high precision, and together

with the gearboxes for axes 2 and 3, forms a complete unit.



The gearbox is not normally serviced or adjusted.

xx0300000007

Required equipment

A M12x50 8.8 hexagon socket head cap screw

B Cover


Art. no.

Note





4 Repair


Refitting

The procedure below details how to refit gearbox, axis 1-3.

WARNING!



result in burns!




NOTE!




replacing.



1. Fit and secure the 12 screws complete with washers .

54 Nm.

2. Place the gearbox upside-down on a table or similar surface and refit the bottom plate

3. Refit the motor, axis 1. Detailed in Refitting of motor, axis 1 on page 143.



6. Refit the complete lower arm. Detailed in Refitting of complete lower arm on page 114.




4 Repair

4.8.3. Remove the complete drive mechanism. IRB 2400L


Location

The drive mechanism is defined as the gears and drive belts to axes 5 and 6. This is shown in

the figure below.

xx0300000012

Required equipment

Removal

The procedure below details how to remove the Drive Shaft Unit from the robot upper arm.

NOTE! ABB recommends its customers to carry out only the following servicing and repair

work on the Drive Shaft Unit.


Art. no.

Note





4 Repair


WARNING!



result in burns!




NOTE!


used!

NOTE!




1. Dismantle the wrist Described in section Removal of wrist IRB 2400/10/16. on page 93.

2. Loosen the connection box and disconnect the connectors on the motors of axes 5 and 6. Make a note of the motor No. on the motors, to simplify the reconnecting.

Described in section Removal of motor, axis 4-6;IRB 2400L on page 159.

3. Undo screws

xx0300000021

• A: Screws

• B: Motor screws

4. Squeeze the drive shafts together at the tip of the tubular shaft, so they can pass through the tube

5. Pull out the complete drive mechanism of axes 5 and 6.

6. Undo the screws and nuts , holding the motors and remove both motors.

Described in section Removal of motor, axis 4-6;IRB 2400L on page 159.

7. Undo the screws and remove the motor plate.

8. Remove the gear belts.


4 Repair

4.8.4. Refitting of complete drive mechanism. IRB 2400L


Location

The drive mechanism is defined as the gears and timing belts to axis 5 and 6. This is shown

in the figure below.

xx0300000012

Required equipment

Location

The procedure below details how to remove the Drive Shaft Unit from the robot upper arm.

NOTE! ABB recommends its customers to carry out only the following servicing and repair

work on the Drive Shaft Unit.


Art. no. Note





New timing belt 3HAA 2393-1 2 pcs

Mounting Tool 3HAA 7601-050


4 Repair


WARNING!



result in burns!




NOTE!




replacing.



1. Install the belts.

2. Fit the plate using screws and washers.

N.B. Do not forget the nuts on the motors!

3. Fit the motors.

4. Push the motors sideways to tighten the belts, using the tool. Place the round post of the tool into the motor pulley and let the cam press to the outer diameter of the large pulley.

Tool no. 3HAA 7601-050.

Tighten screws B (shown in the illustration below) to 4.1 Nm.

5. Rotate the drive shafts. Check the tension on the belt.

6. Install the drive mechanism in the tubular shaft.

Do not forget the rubber damper.

7. Tighten screws.

xx0300000021

• A: 8.3 Nm

8. Install the cabling and mount the cover to motors axes 5 and 6.

Detailed in Refitting of motor, axis 4-6 on page 162

9. Mount the wrist. Described in sectionRefitting of wrist IRB 2400/10/16 on page 96




4 Repair



5 Calibration information

5.1. Introduction


5.1. Introduction

General

This chapter includes general information about different calibration methods and details also

procedures that does not require specific calibration equipment.

When the robot system must be recalibrated, it is done according to documentation enclosed

with the calibration tools.

When to calibrate

The system must be calibrated if any of the below occurs.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods

supplied from ABB. Calibrate the robot carefully with standard calibration. The different

methods are briefly described in section Calibration methods on page 184, and further

detailed in separate Calibration manuals.

If the robot has Absolute Accuracy calibration, it is also recommended but not always needed

to be calibrated for new Absolute Accuracy.

The resolver values will change when parts affecting the calibration position are replaced on

the robot, e.g. motors, wrist or part of transmission.

Contents of the revolution counter memory are lost

If the contents of the revolution counter memory are lost, the counters must be updated as

detailed in section Updating revolution counters on page 189. 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 are connected at

the first installation.

The robot is rebuilt

If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other

reachability, it needs to be recalibrated for new resolver values.

If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute

Accuracy.

References

The article numbers for the Calibration manuals are listed in section Document references in

the Product manual (part 2 of 2), reference information. Article numbers for the calibration

tools are also listed in part 2 of the Product manual.



5.2. Calibration methods


Overview

This section specifies the different types of calibration and the calibration methods that are

supplied from ABB.

Types of calibration

Type of calibration

Description Calibration method

Standard calibration

The calibrated robot is positioned at home position, i.e. the axes positions (angles) are set to 0º.

Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position.

From deliveries together with RobotWare 5.0.5 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

Calibration Pendulum (standard method)

or

Levelmeter calibration (alternative method)

Absolute Accuracy calibration (optional)

Based on standard calibration, but besides positioning the robot at home position, the Absolute Accuracy calibration also compensates for:

• mechanical tolerances in the robot structure

• deflection due to load.

Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot.

Absolute Accuracy data is found in the file absacc.cfg, supplied with the robot at delivery. The file replaces the calib.cfg file and identifies motor positions as well as absacc-compensation parameters.

From deliveries together with RobotWare 5.0.6 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

A robot calibrated with AbsAcc has a sticker next to the identification plate of the robot.

To regain 100% Absolute Accuracy performance, the robot must be recalibrated for Absolute Accuracy!

xx0400001197

CalibWare




Calibration methods

Each calibration method is detailed in separate manuals. Below is a brief description of the

methods available.

Calibration Pendulum - standard method

Calibration 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 most accurate method for the

standard type of calibration. It is the recommended method in order to achieve proper

performance.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,

including the manual Calibration Pendulum Instruction.

Levelmeter Calibration - alternative method

Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots,

because of the less accurate values obtained during calibration. The method uses the same

principles as Calibration Pendulum but has not as good mechanical tolerances to the toolkit

parts as the standard method with Calibration Pendulum.

This method may, after calibration, require modifications in the robot program, and is therefor

not recommended.

The calibration equipment for Levelmeter Calibration is ordered as separate parts for each

robot and the manual Instruction for Levelmeter Calibration is enclosed with the Levelmeter

2000.

CalibWare - Absolute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy

is used as a TCP calibration. The tool CalibWare guides through the calibration process and

calculates new compensation parameters. This is detailed further in the manual xx.

If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy

calibration is required in order to establish full performance. For most cases after motor and

transmission replacements that do not include taking apart the robot structure, standard

calibration is sufficient. Standard calibration also supports wrist exchange.



5.3. Calibration scales and correct axis position


Introduction

This section specifies the calibration scale positions and/or correct axis position for all robot

models.

Calibration scales, IRB 2400

The illustration below shows the calibration scale positions on IRB 2400:




en0200000273



5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes

Calibration movement directions

When calibrating, the axis must consistently be run towards the calibration position in the

same direction, in order to avoid position errors caused by backlash in gears etc. Positive

directions are shown in the figure below.

This is normally handled by the robot calibration software.

Note! The figure shows an IRB 7600, but the positive direction is the same for all robots,

except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!

xx0200000089



5.5. Updating revolution counters


General

This section details how to perform a rough calibration of each robot axis, i.e. updating the

revolution counter value for each axis, using either the TPU or the FlexPendant.

Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter; manually running

the robot to the calibration position.

Correct calibration position of axis 4 and 6

When running the robot to calibration position, it is extremely important to make sure that

axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have

any mechanical stops and can therefore be calibrated at the wrong turn.

Make sure the axes are positioned according to the correct calibration values, not only

according to the calibration marks. The correct values are found on a label, located either on

the lower arm or underneath the flange plate on the base.

At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before

the revolution counters are updated.

If one of the below mentioned axes are rotated one or more turns from its calibration position

before updating the revolution counter, the exact calibration position will be lost due to

uneven gear ratio. This affects the following robots:

Step Action Note

1. Select axis-by-axis motion mode.

2. Jog the robot so that the calibration marks lie within the tolerance zone.

Shown in section Calibration scales and correct axis position on page 186.

3. When all axes are positioned, store the revolution counter settings.

Detailed in sections:

Storing the revolution counter setting with the TPU on page 190 (RobotWare 4.0).

Storing the revolution counter setting with the FlexPendant on page 191 (RobotWare 5.0).

Robot variant Axis 4 Axis 6

IRB2400L (5kg) Yes No




Storing the revolution counter setting with the TPU

This section details the second step when updating the revolution counter; storing the

revolution counter setting with the TPU (RobotWare 4.0).

Step Action Note

1. Press the button "Miscellaneous" then ENTER to select the service window.

xx0100000194

2. Select Calibration from the View menu.

The Calibration window appears.

If there is more than one unit connected to the robot, they will be listed in the window.

xx0100000201

3. Select the desired unit and choose Rev Counter Update from the Calib menu.

The Revolution Counter Update window appears.

xx0100000202

4. Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes.

5. Press OK when all axes that are to be updated are marked with an x.

CANCEL returns to the Calibration window.




Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the

revolution counter setting with the FlexPendant (RobotWare 5.0).

6. Press OK again to confirm and start the update.

CANCEL returns to the Revolution Counter Update window.

7. At this point, it is recommended that the revolution counter values are saved to a diskette.

Not required.

8.

-

Caution!If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

How to perform the check is detailed in section Checking the calibration position on page 193.

Step Action Note

Step Action

1. On the ABB menu, tap Calibration.

All mechanical units connected to the system are shown along with their calibration status.

2. Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters.

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3. Tap Update revolution counters....A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

4. 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.

5. 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 the list of axes.

6.

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Caution!If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

See section Checking the calibration position on page 193.

Step Action



5.6. Checking the calibration position


General

Check the calibration position before beginning any programming of the robot system. This

may be done in one of two ways:

• Using a MoveAbsJ instruction with argument zero on all axes

• Using the Jogging window on the teach pendant

Using a MoveAbsJ instruction on the TPU, S4Cplus

This section describes how to create a program, which runs all the robot axes to their zero

position

Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero

position.

Step Action Note

1. Crate a new program

2. Use MoveAbsJ

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. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in section Calibration scales and correct axis position on page 186.

How to update the revolution counters is detailed in section Updating revolution counters on page 189

Step Action Note

1. On ABB menu tap Program Editor.

2. Create a new program.

3. Use MoveAbsJ in the Motion&Proc menu.

4. Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs, v1000, z50, Tool0

5. Run the program in manual mode.



How to update the revolution counters is detailed in section Updating revolution counters on page 189.




Using the Jogging window on the TPU, S4Cplus

This section describes how to jog the robot to all axes zero position.

Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.

Step Action Illustration/information

1. Open the Jogging window.

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2. Choose running axes-by-axes.

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3. Manually run the robot axes to a position where the axis position value read on the TPU, is equal to zero.



Detailed in section Updating revolution counters on page 189.

Step Action Note

1. Tap Jogging in the ABB menu.

2. Tap Motion mode to choose group of axes to jog.

3. Tap axes 1-3 to jog axes 1, 2 or 3.

4. Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero.



How to update the counters is detailed in section Updating revolution counters on page 189.


Index

C

Calibration position 189calibration position, checking 193calibration position, jog to 194Connection of external safety devices 15

D

direction of axes 188

L

Limitation of Liability 16

N

negative directions, axes 188

P

positive directions, axes 188

R

Revolution counters 189

S

Safety, service 15

U

Updating revolution counters 189

V

Validity and responsibility 15



