ABB IRB 2400/L Product Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Robotics
  5. IRB 2400/L
  6. Product manual

ABB IRB 2400/L Product Manual

Articulated robot
Hide thumbs Also See for IRB 2400/L:
Table of Contents

Advertisement

Quick Links

See also: Product Manual
Product manual
Articulated robot
IRB 2400/L
IRB 2400/10
IRB 2400/16
M2000, M2000A, M2004

Advertisement

Table of Contents
loading

Related Manuals for ABB IRB 2400/L

Summary of Contents for ABB IRB 2400/L

  • Page 1 Product manual Articulated robot IRB 2400/L IRB 2400/10 IRB 2400/16 M2000, M2000A, M2004...
  • Page 3 Product manual IRB 2400/L IRB 2400/10 IRB 2400/16 M2000 M2000A M2004 Document ID: 3HAC022031-001 Revision: C...
  • Page 4 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.

  • Page 5: Table Of Contents

    Table of Contents Overview ................7 How to read the product manual.
  • Page 6 Table of Contents 3 Maintenance 3.1 Introduction ............... 65 3.2 Maintenace schedule .
  • Page 7 7.5 Spare parts - upper arm, IRB 2400/L ....... . .
  • Page 8 Table of Contents 3HAC022031-001 Revision: C...

  • Page 9: Overview

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 10 Overview Continued References Procedures in this product manual contain references to the following manuals: Document name Document ID Note Product specification - IRB 2400 3HAC9112-1 Product manual - IRC5 3HAC021313-001 Product manual - S4Cplus M2000 3HAC021333-001 Product manual - S4Cplus M2000A 3HAC022419-001 Operating manual - IRC5 with FlexPendant 3HAC16590-1...
  • Page 11 Overview Continued Revision Description Cleanroom added. Changes made in: • Prerequisites in section Overview • Oil change in section Maintenance 3HAC022031-001 Revision: C...

  • Page 12: How To Read The Product Manual

    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.

  • Page 13: Product Documentation, M2000/M2000A

    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: •...

  • Page 14: Product Documentation, M2004

    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.
  • Page 15 Product documentation, M2004 Continued Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. The group of manuals includes: • Emergency safety information •...
  • Page 16 Product documentation, M2004 3HAC022031-001 Revision: C...

  • Page 17: Safety

    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 •...

  • Page 18: General Safety Information

    Limitation of liability Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 19: Safety Risks

    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 •...
  • Page 20 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the robot! Touching motors and gears may result in burns! With higher environment temperature more surfaces on the robot are getting HOT and may result in burns too! Removed parts may result in collapse of robot!

  • Page 21: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.2. Safety risks related to tools/workpieces 1.2.2.2. Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).

  • Page 22: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.3. Safety risks related to pneumatic/hydraulic systems 1.2.2.3. 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. After shutdown, particular care must be taken.

  • Page 23: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. 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.

  • Page 24: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.5. Risks associated with live electric parts 1.2.2.5. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, need 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.
  • Page 25 1 Safety 1.2.2.5. Risks associated with live electric parts Continued Voltage related risks, IRC5 controller A danger of high voltage is associated with, for example, the following parts: • Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

  • Page 26: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. 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.

  • Page 27: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot system (robot or controller)! 3HAC022031-001 Revision: C...

  • Page 28: Emergency Release Of The Robot's Arm

    1 Safety 1.2.3.3. Emergency release of the robot’s arm 1.2.3.3. 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. How to release the brakes is detailed in section: •...

  • Page 29: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake 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 the holding brake of each axis motor may be checked as detailed below: 1.

  • Page 30: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC022031-001 Revision: C...

  • Page 31: Safe Use Of The Flexpendant

    1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant NOTE! The enabling device is a push button located on the side of the FlexPendant 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.

  • Page 32: Work Inside The Robot's Working Range

    1 Safety 1.2.3.7. Work inside the robot's working range 1.2.3.7. Work inside the robot'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.

  • Page 33: Translate The Information On Safety And Information Labels

    Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 34: Safety Related Instructions

    1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general 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: •...
  • Page 35 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.

  • Page 36: Danger - Moving Robots Are Potentially Lethal

    1 Safety 1.3.2. DANGER - Moving robots are potentially lethal! 1.3.2. DANGER - Moving robots are potentially lethal! Description Any moving robot is a potentially lethal machine. When running the robot, 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 working range of the robot.

  • Page 37: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.3.3. DANGER - First test run may cause injury or damage! 1.3.3. DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):...

  • Page 38: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.4. WARNING - The unit is sensitive to ESD! 1.3.4. WARNING - The unit is sensitive to ESD! Description ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.

  • Page 39: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.3.5. WARNING - Safety risks during work with gearbox oil 1.3.5. 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...
  • Page 40 1 Safety 1.3.5. WARNING - Safety risks during work with gearbox oil 3HAC022031-001 Revision: C...

  • Page 41: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 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. 3HAC022031-001 Revision: C...

  • Page 42: Unpacking

    2 Installation and commissioning 2.2.1. Pre-installation procedure 2.2 Unpacking 2.2.1. Pre-installation procedure 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 robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the robot:...
  • Page 43 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued IRB 2400 - L Endurance load Max. load (emergency Forces and torques (operation) stop) Force xy ± 1700 N ± 2100 N Force z, upright 4100 ± 1100 N 4100 ± 1400 N Force z, suspended - 4100 ±...

  • Page 44: Working Range

    2.2.2. Working range 2.2.2. Working range Working range This section specifies the working areas of the robot models. IRB 2400/L The working area is the same for both floor and inverted (suspended). Positions are located at wrist center. xx0200000159 Pos.
  • Page 45 2 Installation and commissioning 2.2.2. Working range Continued IRB 2400/10, /16 The working area is the same for both floor and inverted (suspended). Positions are located at wrist center. xx0200000160 Pos. Angle axis 2 Angle axis 3 1455 2041 1351 -118 -302 18.3...

  • Page 46: On-Site Installation

    2 Installation and commissioning 2.3.1. Lifting robot with lifting slings 2.3 On-site installation 2.3.1. Lifting robot with lifting slings General This section details how to lift the robot using lifting slings. Required equipment Equipment Note Sling line Type: KDBK 7-8. Length: 2 m.

  • Page 47: Manually Releasing The Brakes

    2 Installation and commissioning 2.3.2. Manually releasing the brakes 2.3.2. Manually releasing the brakes General The holding brakes of each axis’ motor are of an electromechanical type and are released when voltage is applied. This section details how to release the brakes, using the internal brake release unit, in order to enable the axes to move manually.
  • Page 48 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Supplying power to connector R1.MP If the robot is not connected to the controller, power must be supplied to connector R1.MP in the robot base in order to enable the brake release unit on the robot. Action Note/Illustration CAUTION!

  • Page 49: Orienting And Securing The Robot

    2 Installation and commissioning 2.3.3. Orienting and securing the robot 2.3.3. Orienting and securing the robot General This section details how to orient and secure the robot 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 base plate or the base to a concrete floor, follow the general instructions for expansion-shell bolts.
  • Page 50 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Cross section, guide sleeve hole The figure below shows the cross section of the guide sleeve holes (from previous figure): xx0200000182 Guide sleeves 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.

  • Page 51: Suspended Mounting

    2 Installation and commissioning 2.3.4. Suspended mounting 2.3.4. Suspended mounting General The robot can be mounted in a suspended position. This section details how to turn the robot. Turning the robot 1. Use the special tool for inverted mounting, see following figure. xx0200000212 Lifting beam Fork lift...

  • Page 52: Loads

    Specification. The loads must also be defined in the software as detailed in User's Guide (RobotWare 4.0), or Operating manual - IRC5 with FlexPendant. Stop time and braking distances Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC022031-001 Revision: C...

  • Page 53: Restricting The Working Range

    2 Installation and commissioning 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 following axes may be restricted: •...

  • Page 54: Mechanically Restricting The Working Range Of Axis 1

    2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 2.4.2. Mechanically restricting the working range of axis 1 Restrictions in the working range The working range of axis 1 can be restricted within the area from 50º to 140º as shown in the figure below.
  • Page 55 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Required equipment Equipment Art. no. Note Stop, axis 1 3HAB 7298-1 Includes: • removable stop (2 pcs) • plain washers (4 pcs) • hex socket head cap screw (4 pcs, M12x30) •...
  • Page 56 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Action Note WARNING! If the mechanical stop is deformed after a hard collision, it must be replaced! Location of where to drill holes for extra stops The figure below shows the drill pattern used when drilling for mechanical stops on axis 1.
  • Page 57 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued The minimum and maximum measurement between the mechanical stops. The difference between the measurement and the minimum and maximum working range is 2 x 4º, which corresponds to the width of the stop pin (at the frame). Hidden stiffening ribs and forbidden drilling sector xx0600002647 Drilling not allowed inside this sector!
  • Page 58 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Drill template xx0200000207 3HAC022031-001 Revision: C...
  • Page 59 2 Installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 2.4.3. Mechanically restricting the working range of axis 2 General The range of rotation for axis 2 can be limited mechanically by fitting extra stops on the lower arm.
  • Page 60 2 Installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 Continued Equipment Art. no. Note Standard toolkit The content is defined in section Standard toolkit on page 178. 3HAC022031-001 Revision: C...

  • Page 61: Installation Of Limit Switch, Axis 3

    2 Installation and commissioning 2.4.4. Installation of limit switch, axis 3 2.4.4. Installation of limit switch, axis 3 General The working range of axis 3 can be limited by fitting an electrical switch on the gearbox axis 3, which senses the position via a cam. Mounting of eletrical stop Following illustration shows howe to fit the electrical stop.

  • Page 62: Electrical Connections

    2 Installation and commissioning 2.5.1. Connectors on robot 2.5 Electrical connections 2.5.1. Connectors on robot Connectors on the robot The figure below shows all connections of the robot cabling, including the customer connections. xx0500002039 3HAC022031-001 Revision: C...

  • Page 63: Robot Cabling And Connection Points

    2 Installation and commissioning 2.5.2. Robot cabling and connection points 2.5.2. Robot cabling and connection points General Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories All cables between the robot and controller are divided into the following categories: Cable category...
  • Page 64 2 Installation and commissioning 2.5.2. Robot cabling and connection points Continued Cable Art. no. Robot cable, power, 30 m 3HAC9038-4 Robot cable, signals Cable Art. no. Robot cable, signal, shielded, 7 m 3HAC7998-1 Robot cable, signal, shielded, 15 m 3HAC7998-2 Robot cable, signal, shielded, 22 m 3HAC7998-3 Robot cable, signal, shielded, 30 m...

  • Page 65: Making Robot Ready For Operation (Cleanroom)

    2 Installation and commissioning 2.6.1. Additional installation procedure. 2.6 Making robot ready for operation (Cleanroom) 2.6.1. Additional installation procedure. General Cleanroom robots are specially designed to work in a cleanroom environment. Cleanroom robots are designed in order to prevent from particle emission from the robot. For example some articles in the robot's design, which normally are exposed to some wear during operation, are unpainted.
  • Page 66 2 Installation and commissioning 2.6.1. Additional installation procedure. 3HAC022031-001 Revision: C...

  • Page 67: Maintenance

    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 intervals and refers to procedures for the activities.

  • Page 68: Maintenace Schedule

    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: •...

  • Page 69: Maintenance Schedule

    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.

  • Page 70: Changing Activites

    Mobilgear 600 XP320 11712016-604 30 ml Axis 4 (IRB 2400/10/16) Optimol BM 100 3HAC 0860-1 1,500 ml Axis 5 and 6 (IRB 2400/L) Mobilgear 600 XP320 11712016-604 120 ml Axis 5 and 6 (IRB 2400/10/16) Optimol BM 100 3HAC 0860-1 800 ml...

  • Page 71: Oil Change, Gearbox Axes 5-6 (Wrist Unit)

    Oil plug Oil plug (air inlet when draining from oil plug A) Required equipment Equipment Art. no. Volume Note Lubricating oil, IRB 2400/L 11712016-604 120 ml Mobilgear 600 XP320 Lubricating oil, IRB 2400/10/16 3HAC 0860-1 800 ml Optimol BM 100 Oil collecting vessel Capacity: 200 ml.
  • Page 72 3 Maintenance 3.3.2. Oil change, gearbox axes 5-6 (wrist unit) Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section WARNING - Safety risks during work with gearbox oil on...
  • Page 73 3 Maintenance 3.3.2. Oil change, gearbox axes 5-6 (wrist unit) Continued Action Note WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section WARNING - Safety risks during work with gearbox oil on page 4.

  • Page 74: Replacement Of Smb Battery Unit

    3 Maintenance 3.3.3. Replacement of SMB battery unit 3.3.3. Replacement of SMB battery unit Location of SMB battery unit The SMB battery unit is located inside the robot base, as shown in the figure below. xx0300000067 SMB battery SMB battery cable Required equipment Equipment Spare part no.
  • Page 75 3 Maintenance 3.3.3. Replacement of SMB battery unit Continued Replacement, SMB battery The procedure below details how to replace the SMB battery. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! The unit is sensitive to ESD, before handling the unit please observe the safety information in section WARNING - The unit is sensitive to...
  • Page 76 3 Maintenance 3.3.3. Replacement of SMB battery unit 3HAC022031-001 Revision: C...

  • Page 77: Repair

    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 procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, for example spare parts numbers, required special tools and materials.

  • Page 78: General Procedures

    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 gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.

  • Page 79: Mounting Instructions For Bearings

    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 robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB3537-1 Used to grease the bearings, if not specified otherwise.
  • Page 80 4 Repair 4.2.2. Mounting instructions for bearings Continued 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.

  • Page 81: Mounting Instructions For Seals

    4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 82 If the flange surfaces are defective, the parts may not be used because leakage could occur. 2. Clean the surfaces properly and in accordance with ABB recommendations. 3. Distribute the sealing compound evenly over the surface, preferably with a brush.

  • Page 83: Complete Robot

    4 Repair 4.3.1. Replacement of cable unit, axes 1-3 4.3 Complete robot 4.3.1. Replacement of cable unit, axes 1-3 Location of cabling The cable unit of axes 1-3 is run from the base of the robot to the motors, axes 1, 2 and 3, as shown in the figure below.
  • Page 84 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Equipment, etc. Spare part no. Art. no. Note Sealing 3HAC4113-1 Sealing in the base for the cables. Always use a new sealing. Gasket, cover 3HAC3200-1 Cable straps, outdoor 2166 2055-3 Flange sealing 12340011-116 Loctite 574...
  • Page 85 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Action Note/Illustration 6. Loosen the nuts (D) and remove the SMB unit 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.
  • Page 86 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Action Note/Illustration 11. Remove the cover of the motors 1-3. 12. Disconnect all the connectors at the motors of axes 1, 2 and 3. xx0200000401 A. R3.MP1-3 B. R3.FB1-3 C. Connection box 13.
  • Page 87 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Action Note/Illustration 6. Refit the upper bracket securing the cables to the arm house, using the two attachment screws. 7. Fit the cable guide to the harness and secure the holder to the frame with its two attachment screws (A).
  • Page 88 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Action Note/Illustration 10. Refit 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). 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.

  • Page 89: Replacement Of Cable Harness, Axes 4-6

    4 Repair 4.3.2. Replacement of cable harness, axes 4-6 4.3.2. Replacement of cable harness, axes 4-6 Location of cable harness The cable harness runs throughout the robot as shown in the figure below. xx0200000396 Connector at robot base, R1.MP, R1.SMB and R1.C/CS Electrical connectors rear of the cover plate at the robot base , R1.MP1-3, R1.MP4-6, R1.CS, R1.CP, R1.H1, R2.BU, R2.BU1-3, R2.BU4-6, Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G...
  • Page 90 3HAC 9330-1 IRB 2400/L Cable unit axes 4-6 3HAC9328-1 IRB 2400 /10, /16 Cable unit, axes 4-6 Opt 3HAC 8520-1 IRB 2400/L Option 043 Gasket, motor axes 4-6 3HAC4429-1 Sealing 3HAB 5922-1 Flange sealing 12340011-116 Loctite 574 Cable straps, outdoor...
  • Page 91 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Action Note/Illustration 4. Disconnect connectors R1.MP4-6 and R2.BU4-6. 5. Disconnect all the earth cables on the R1.M4-6 cable from the back of the cover. xx0200000403 6. Loosen the nuts (D) holding the SMB-unit slightly, then remove it carefully from the bracket.
  • Page 92 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Action Note/Illustration 9. Remove the adapter plate from the harness by removing its two attachment screws (A). xx0200000404 Note! Different robot versions are fitted with different plate versions. Make sure the correct one is used to avoid cable failure.
  • Page 93 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Refitting, cable harness, axes 4-6 The procedure below details how to refit the cable harness, axes 4-6. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 94 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Action Note/Illustration 5. 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...
  • Page 95 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Action Note/Illustration 7. Fit the upper bracket securing the cables to the arm house, using the two attachment screws. 8. Fit the adapter plate to the harness by using its two attachment screws (A). xx0200000404 Note! Different robot versions are fitted with different plate versions.
  • Page 96 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Action Note/Illustration 11. Fit 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). 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.

  • Page 97: Upper Arm

    4 Repair 4.4.1. Replacement of wrist IRB 2400/10/16 4.4 Upper arm 4.4.1. Replacement of wrist IRB 2400/10/16 Location of wrist The wrist is defined as the axis 5 and 6 of the robot. This is shown in pos (A) in the figure below.
  • Page 98 4 Repair 4.4.1. Replacement of wrist IRB 2400/10/16 Continued Wrist unit xx0300000104 Attachment screws and washers Oil plug Wrist Required equipment Equipment, etc. Spare part no. Art. no. Note Wrist 3HAB9398-1 O-ring 3HAB3772-12 Replace if damaged. Grease 3HAB3537-1 Shell Alvania WR2 Guide pins M8, length = 70 mm Measuring tool...
  • Page 99 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.
  • Page 100 4 Repair 4.4.1. Replacement of wrist IRB 2400/10/16 Continued Action Note/Illustration 6. In order to release the brakes, connect the 24 VDC Connect to motor axis 5, power supply to the motor. connector R3.MP5: Note! Release the brakes of the two motors, but one •...

  • Page 101: Replacement Of Wrist Irb 2400L

    4 Repair 4.4.2. Replacement of wrist IRB 2400L 4.4.2. Replacement of wrist IRB 2400L Location of wrist The wrist is defined as the axis 5 and 6 of the robot and shown in pos (A) in the figure below. x0300000409 Wrist Upper arm Lower arm...
  • Page 102 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.
  • Page 103 4 Repair 4.4.2. Replacement of wrist IRB 2400L Continued Action Note 6. Refit the plugs. 7. Refit the cover at the motor side of axis 5-6. 8. Calibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

  • Page 104: Replacement Of Complete Upper Arm

    4 Repair 4.4.3. Replacement of complete upper arm 4.4.3. Replacement of complete upper arm Location of upper arm The upper arm is located on top of the robot as shown in (A) and (B) the figure below. The complete upper arm includes the wrist unit. xx0200000409 Wrist axis 5-6 Upper arm axis 3-4...
  • Page 105 4 Repair 4.4.3. Replacement of complete upper arm Continued Upper arm attachment xx0200000436 Cover KM nuts Attachment screw Sealing (insert a strap under the sealing to let the air go out when fitting the cover) Removal, upper arm The procedure below details how to remove the complete upper arm. Action Note/Illustration DANGER!
  • Page 106 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 8. Fit the lifting device to the upper arm, and lift enough for the strap to stretch without lifting the robot. xx0200000435 Lifting without lifting tool! 9. Pull out the shaft, using the dismounting tool for Art.
  • Page 107 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note 10. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 159. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 108: Lower Arm

    4 Repair 4.5.1. Replacement of complete lower arm 4.5 Lower arm 4.5.1. Replacement of complete lower arm Location of lower arm The lower arm is located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual.
  • Page 109 4 Repair 4.5.1. Replacement of complete lower arm Continued Equipment, etc. Spare part no. Art. no. Note Hoisting equipment Standard toolkit The content is defined in section Standard toolkit on page 178. Calibration Pendulum 3HAC15716-1 Complete kit that also toolkit includes operating manual.
  • Page 110 4 Repair 4.5.1. Replacement of complete lower arm Continued Action Note/Illustration 4. Fit the lifting equipment to the lower arm to secure its weight. xx0200000439 5. Remove the tie rod. Detailed in section Removal, tie rod on page 112. 6. Remove the parallel arm. Detailed in section Removal, parallel arm on page...
  • Page 111 4 Repair 4.5.1. Replacement of complete lower arm Continued Refitting, lower arm The procedure below details how to refit the complete lower arm. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Move the damper and calibration marking to the new lower arm.

  • Page 112: Replacement Of Tie Rod

    4 Repair 4.5.2. Replacement of tie rod 4.5.2. Replacement of tie rod Location of tie rod The tie rod is located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual.
  • Page 113 4 Repair 4.5.2. Replacement of tie rod Continued xx0200000443 Bearing sealing Back up ring Attachment screw Locking washer Spherical roller bearing Upper connection IRB 2400 5 kg Bearing sealing Spherical roller bearing Bearing sealing Screw Required equipment Equipment, etc. Spare part no. Art. no. Note Locking liquid 3HAB7116-1...
  • Page 114 4 Repair 4.5.2. Replacement of tie rod Continued Equipment, etc. Spare part no. Art. no. Note Other tools and procedures These procedures include may be required. See references to the tools references to these required. procedures in the step-by- step instructions below. Removal, tie rod The procedure below details how to remove the tie rod from the robot.
  • Page 115 4 Repair 4.5.2. Replacement of tie rod Continued Action Note 3. Fit the new spherical roller bearings to the Shown in the figure Location of tie rod on tie rod using the press tool, parallel bar page 110. bearing. Lubricate the bearings with bearing Art.

  • Page 116: Frame And Base

    4 Repair 4.6.1. Replacement of SMB unit 4.6 Frame and base 4.6.1. Replacement of SMB unit Location of SMB unit The SMB unit (SMB = serial measurement board) is located on the left hand side of the base, as shown in the figure below. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181...
  • Page 117 4 Repair 4.6.1. Replacement of SMB unit Continued Equipment Spare part no. Art. no. Note Standard toolkit The content is defined in section Standard toolkit on page 178. Circuit Diagram See chapter Circuit diagram. Other tools and These procedures include procedures may be references to the tools required.
  • Page 118 4 Repair 4.6.1. Replacement of SMB unit Continued Replacement, SMB unit The procedure below details how to replace the SMB unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the rear cover plate (A) from the base by unscrewing the attachment screws (B).

  • Page 119: Replacement Of Brake Release Unit

    4 Repair 4.6.2. Replacement of brake release unit 4.6.2. Replacement of brake release unit Location of brake release unit The brake release unit is located behind the flange plate at the robot base, as shown below. xx0200000459 Brake release unit with buttons Required equipment Equipment, etc.
  • Page 120 4 Repair 4.6.2. Replacement of brake release unit Continued Action 5. Disconnect the cable from the brake release unit and remove the unit from the base. 6. Reconnect the cable to the new brake release unit and fit it to the base. 7.

  • Page 121: Replacement Of Parallel Arm

    4 Repair 4.6.3. Replacement of parallel arm 4.6.3. Replacement of parallel arm Location of parallel arm The parallel arm is located at the frame, as shown in the figure below. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual.
  • Page 122 4 Repair 4.6.3. Replacement of parallel arm Continued Removal, parallel arm The procedure below details how to remove the parallel arm. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the tie rod. Detailed in section Removal, tie rod on page...
  • Page 123 4 Repair 4.6.3. Replacement of parallel arm Continued Refitting, parallel arm The procedure below details how to refit the complete parallel arm to the robot. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 124: Motors

    4 Repair 4.7.1. Replacement of motor, axis 1 4.7 Motors 4.7.1. Replacement of motor, axis 1 Location of motor, axis 1 The motor, axis 1, is located on the left hand side of the robot as shown in the figure below: A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181...
  • Page 125 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Required equipment Note! The different motors are not compatible. Make sure to replace with correct model! Equipment Spare part no. Art. no. Note Motor axis 1 3HAC4789-1 IRB 2400 /L, /10, /16 (Elmo) 3HAC14271-1 IRB 2400 /Wall mounted...
  • Page 126 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Action Note/Illustration 3. Disconnect the connectors R3.MP1 and R3.FB1. xx0200000401 • A: R3.MP1 • B: R3.FB1 • C: Connection box 4. Remove the connection box by unscrewing its Shown in the figure Location of three attachment screws and plain washers.
  • Page 127 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Action Note/Illustration 4. Fit the motor by gently lowering it straight down. Note the position of the motor! Use the mark , made on the motor base before removal. See also orientation of the holes on top of the motor, shown in the figure Location of...
  • Page 128 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Action Note/Illustration 15. Reconnect the connectors R3.MP1 and R3.FB1. xx0200000406 • A: R3.MP1 • B: R3.FB1 • C: Connection box 16. Refit the cover of the connection box. Shown in the figure Location of motor, axis 1 on page 122.

  • Page 129: Replacement Of Motor, Axis 2

    4 Repair 4.7.2. Replacement of motor, axis 2 4.7.2. Replacement of motor, axis 2 Location of motor, axis 2 The motor, axis 2, is located on the left hand side of the robot as shown in the figure below: xx0200000470 Attachment screws, cover (5 pcs) Cover Connection box...
  • Page 130 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Required equipment Note! The different motors are not compatible. Make sure to replace with correct model! Equipment, etc. Spare part no. Art. no. Note Motor, axis 2 3HAC4790-1 (Elmo) Motor, axis 2 3HAC021350-001 (Yaskawa) O-ring...
  • Page 131 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Action Note/Illustration 4. Remove the connection box by unscrewing its three attachment screws and plain washers. 5. Use a marker pen to mark out the position of the motor, if the same motor is to be refitted. Secure the robot arms before unscrewing any of the attachment screws of the axis 2 motor.
  • Page 132 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Action Note/Illustration 3. Fit the o-ring. Always fit a new one, see art. no. in Required equipment on page 128. 4. Fit the motor by gently lifting it straight on. Note the position of the motor! Use the mark on the motor base, made before removing the motor.
  • Page 133 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Action Note/Illustration 14. Perform a leak-down test. Detailed in section Performing a leak-down test on page 15. Fill the gearbox with oil. Type and amount of oil is specified in section Oil in gearboxes on page 16.

  • Page 134: Replacement Of Motor, Axis 3

    4 Repair 4.7.3. Replacement of motor, axis 3 4.7.3. Replacement of motor, axis 3 Location of motor, axis 3 The motor, axis 3, is located on the right hand side of the robot, as shown in the figure below: A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual.
  • Page 135 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Required equipment Note! The different motors are not compatible. Make sure to replace with correct model! Equipment Spare part no. Art. no. Note Motor axis 3 3HAC4789-1 (Elmo) 3HAC021346-001 (Yaskawa) Gasket 3HAB3676-1 O-ring 3HAB3772-1...
  • Page 136 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Action Note/Illustration 4. Remove the connection box by unscrewing its Shown in the figure Location of three attachment screws and plain washers. motor, axis 3 on page 132. 5. Use a marker pen to mark out the position of the motor, if the same motor is to be refitted.
  • Page 137 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Action Note/Illustration 3. Fit a new o-ring to the motor. Always mount a new one, see art. no. in section Required equipment on page 133. 4. Fit the motor, by gently lifting it straight on. Note the position of the motor! Use the mark on the motor base, made before removal.
  • Page 138 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Action Note/Illustration 14. Perform a leak-down test. Detailed in section Performing a leak- down test on page 15. Refill the gearbox with oil. Type and amount of oil is specified in section Oil in gearboxes on page 16.

  • Page 139: Replacement Of Motors, Axes 4-6, Irb 2400L

    4 Repair 4.7.4. Replacement of motors, axes 4-6, IRB 2400L 4.7.4. Replacement of motors, axes 4-6, IRB 2400L Location of motors axes 4-6 The motor of axis 4 is located on the right hand side of the robot as shown in the figure below: The motors of axes 5 and 6 are located on the back side of the robot as shown in the figure below: A more detailed view of the component and its position may be found in chapter...
  • Page 140 4 Repair 4.7.4. Replacement of motors, axes 4-6, IRB 2400L Continued Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, max. 1.5 A. For releasing the brakes. Standard toolkit The content is defined in section Standard toolkit on page 178.
  • Page 141 4 Repair 4.7.4. Replacement of motors, axes 4-6, IRB 2400L Continued Removal, motor axis 4 The procedure below details how to remove the motor, axis 4. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 142 4 Repair 4.7.4. Replacement of motors, axes 4-6, IRB 2400L Continued Action Note/Illustration 5. Fit the measuring tool at the rear of the motor. xx0300000005 6. 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 7.
  • Page 143 4 Repair 4.7.4. Replacement of motors, axes 4-6, IRB 2400L Continued Action Note/Illustration DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page Refitting, motor axis 5 The procedure below details how to refit the motor, axis 5.
  • Page 144 4 Repair 4.7.4. Replacement of motors, axes 4-6, IRB 2400L Continued Action Note 10. Reconnect the cabling. Described in Refitting, cable harness, axes 4-6 on page 11. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.
  • Page 145 4 Repair 4.7.4. Replacement of motors, axes 4-6, IRB 2400L Continued Action Note 7. Find the smallest play by turning the outgoing shaft for axis 4 in intervals of 90°, totally one whole turn, and thereby finding the area where the play for motor 6 becomes smallest.

  • Page 146: Replacement Of Motors, Axes 4-6, Irb 2400/10/16

    4 Repair 4.7.5. Replacement of motors, axes 4-6, IRB 2400/10/16 4.7.5. Replacement of motors, axes 4-6, IRB 2400/10/16 Location of motors axis 4-6 The motors axis 4-6 are located on the back of the upper arm as shown in the figure below: A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
  • Page 147 4 Repair 4.7.5. Replacement of motors, axes 4-6, IRB 2400/10/16 Continued Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, max. 1.5 A. For releasing the brakes. Standard toolkit The content is defined in section Standard toolkit on page 178.
  • Page 148 4 Repair 4.7.5. Replacement of motors, axes 4-6, IRB 2400/10/16 Continued Action Note/Illustration 5. Remove the connection box by unscrewing its three attachment screws and plain washers. 6. Use a marker pen to mark out the position of the motors, if same motors are to be refitted.
  • Page 149 4 Repair 4.7.5. Replacement of motors, axes 4-6, IRB 2400/10/16 Continued Action Note/Illustration 7. In order to release the brakes, connect the Connect to connector R3.MP4: 24 VDC power supply to the motor. • + : pin 7 • - : pin 8 8.
  • Page 150 4 Repair 4.7.5. Replacement of motors, axes 4-6, IRB 2400/10/16 Continued Action Note 3. Fit a new o-ring on the motor. Spare part no. is specified in Required equipment on page 144. 4. Fit the measuring tool at the rear of the motor. See how to fit the tool in the figure in the procedure Refitting,...
  • Page 151 4 Repair 4.7.5. Replacement of motors, axes 4-6, IRB 2400/10/16 Continued Refitting, motor axis 6 The procedure below details how to refit the motor, axis 6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 152 4 Repair 4.7.5. Replacement of motors, axes 4-6, IRB 2400/10/16 Continued Action Note 11. Recalibrate the robot. Calibration is detailed in a separate calibration manual, (When all service work is done, i.e. the other motors enclosed with the calibration tools. are also refitted.) General calibration information is included in section...

  • Page 153: Gearboxes

    4 Repair 4.8.1. Replacement of gearbox, axis 1-3 4.8 Gearboxes 4.8.1. Replacement 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. Together with the gearboxes for axes 2 and 3, it forms a complete unit.
  • Page 154 4 Repair 4.8.1. Replacement of gearbox, axis 1-3 Continued Removal, gearbox axis 1-3 The procedure below details how to remove the gearbox, axis 1-3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 155 4 Repair 4.8.1. Replacement of gearbox, axis 1-3 Continued Action Note 3. Place the gearbox unit upside-down on a table or similar surface. 4. Fit the base to the gearbox unit and secure with 12 pcs; M12x50. Tightening torque: the 12 screws and washers. 54 Nm.

  • Page 156: Replacement Of Drive Shaft Unit, Irb 2400L

    4 Repair 4.8.2. Replacement of drive shaft unit, IRB 2400L 4.8.2. Replacement of drive shaft unit, IRB 2400L Location, drive shaft unit The drive shaft unit is defined as the gears and drive belts to axes 5 and 6. This is shown in the figure below.
  • Page 157 Removal, drive shaft unit 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.
  • Page 158 Refitting, drive shaft unit 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.
  • Page 159 4 Repair 4.8.2. Replacement of drive shaft unit, IRB 2400L Continued Action Note/Illustration DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page 3HAC022031-001 Revision: C...
  • Page 160 4 Repair 4.8.2. Replacement of drive shaft unit, IRB 2400L 3HAC022031-001 Revision: C...

  • Page 161: Calibration Information

    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 160, and further detailed in separate Calibration manuals.

  • Page 162: Calibration Methods

    5 Calibration information 5.2. Calibration methods 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 Description Calibration method calibration Standard The calibrated robot is positioned at home...
  • Page 163 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.

  • Page 164: Calibration Scales And Correct Axis Position

    5 Calibration information 5.3. Calibration scales and correct axis position 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 marks on all axes of the robot. en0200000273 3HAC022031-001 Revision: C...

  • Page 165: Calibration Movement Directions For All Axes

    5 Calibration information 5.4. Calibration movement directions for all axes 5.4. Calibration movement directions for all axes Overview 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.

  • Page 166: Updating Revolution Counters

    5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, that is updating the revolution counter value for each axis, using the pendant. Step 1 - Manually running the robot to the calibration position This procedure details the first step when updating the revolution counter;...
  • Page 167 5 Calibration information 5.5. Updating revolution counters Continued Action Note 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.
  • Page 168 This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Action 1. On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
  • Page 169 5 Calibration information 5.5. Updating revolution counters Continued Action 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: •...

  • Page 170: Checking The Calibration Position

    This section describes how to create a program, which runs all the robot axes to their zero position. 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...
  • Page 171 This section describes how to jog the robot to all axes zero position. Action Note 1. Tap Jogging in the ABB menu. 2. Tap Motion mode to choose group of axes to jog. 3. Tap axis 1-3 to jog axis 1, 2, or 3.
  • Page 172 5 Calibration information 5.6. Checking the calibration position Continued 3HAC022031-001 Revision: C...

  • Page 173: Reference Information

    6 Reference information 6.1. Introduction 6 Reference information 6.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC022031-001 Revision: C...

  • Page 174: Applicable Safety Standards

    6 Reference information 6.2. Applicable safety standards 6.2. Applicable safety standards Standards, general The robot is designed in accordance with the requirements of: • EN ISO 10218-1: 2006 Robots for industrial environments of machines - Safety requirements - Part 1 Robot •...

  • Page 175: Unit Conversion

    6 Reference information 6.3. Unit conversion 6.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 176: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
  • Page 177 6 Reference information 6.4. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure descriptions.
  • Page 178 6 Reference information 6.4. Screw joints Continued Tightening torque (Nm) Tightening torque (Nm) Dimension Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque...

  • Page 179: Weight Specifications

    All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

  • Page 180: Standard Toolkit

    6 Reference information 6.6. Standard toolkit 6.6. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

  • Page 181: Special Tools

    6 Reference information 6.7. Special tools 6.7. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 178, and of special tools, listed directly in the instructions and also gathered in this section.

  • Page 182: Lifting Equipment And Lifting Instructions

    6 Reference information 6.8. Lifting equipment and lifting instructions 6.8. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

  • Page 183: Spare Parts And Exploded Views

    7 Spare parts and exploded views 7.1. Introduction 7 Spare parts and exploded views 7.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC022031-001 Revision: C...

  • Page 184: Spare Parts - Base

    7 Spare parts and exploded views 7.2. Spare parts - base 7.2. Spare parts - base Base, spare part list The spare parts for the base are listed below and shown in the figure Base, spare part view on page 183.
  • Page 185 7 Spare parts and exploded views 7.2. Spare parts - base Continued Base, spare part view xx0500001610 3HAC022031-001 Revision: C...

  • Page 186: Spare Parts - Lower Arm

    7 Spare parts and exploded views 7.3. Spare parts - lower arm 7.3. Spare parts - lower arm Lower arm, spare part list - Foldout 1 The lower arm spare parts listed below are shown in foldout 1. Dimension/ Item Total Qty* Description Spare part no.
  • Page 187 7 Spare parts and exploded views 7.3. Spare parts - lower arm Continued Dimension / Item Total Qty* Description Spare part no. Note Hex socket head cap screw 3HAB3409-50 M10x40 12.9 Spring tension plate 3HAC2205-1 66x116x3 Damper, standard axis 2 3HAC2180-1 Hex socket head cap screw 3HAB3409-57...
  • Page 188 7 Spare parts and exploded views 7.3. Spare parts - lower arm Continued Item Total Qty* Description Spare part no. Dimension Cable guide 3HAB 5924-1 Spring 3HAB 3662-1 Cable guide upper arm 3HAB 5928-1 IRB 2400/10/16 Cover 3HAC 4337-1 Also shown in Foldout 3 Torx pan head roll.
  • Page 189 7 Spare parts and exploded views 7.3. Spare parts - lower arm Continued Item Total Qty* Description Spare part no. Dimension Cable straps, outdoor 21662055-3 L=208 mm Push button unit 3HAC0017-1 Recommended spare part. Distance bolt 21252052-198 Push button cover 3HAC2744-1 Signal cable SMB 3HAC7819-1...
  • Page 190 7 Spare parts and exploded views 7.3. Spare parts - lower arm Continued Item Total Qty* Description Spare part no. Dimension / Note Torx pan head roll 9ADA629-44 M5x12. Also in Foldout 4, screw Also shown in Foldout 3, Cable straps, outdoors 21662055-1 L=101 mm Adhesive tape 11699198-301...
  • Page 196 7 Spare parts and exploded views 7.4. Spare parts - upper arm, IRB 2400/10/16 7.4. Spare parts - upper arm, IRB 2400/10/16 Upper arm, IRB 2400/10/16, spare part list The spare parts for the upper arm, IRB 2400 version /10 and /16, are listed below and shown in the foldouts 6 and 7.
  • Page 197 7 Spare parts and exploded views 7.4. Spare parts - upper arm, IRB 2400/10/16 Continued Item Description Spare part no. Dimension/Note 50 g Grease 3HAB3537-1 30 ml Flange sealing 12340011-116 Loctite 574 Sealing ring without 3HAC7877-2 dust lip Taper roller bearing 3HAA2103-15 32007 X Parallel bar...

  • Page 200: Spare Parts - Upper Arm, Irb 2400/L

    7 Spare parts and exploded views 7.5. Spare parts - upper arm, IRB 2400/L 7.5. Spare parts - upper arm, IRB 2400/L Upper arm, IRB 2400/L, spare part list The spare parts for the upper arm, IRB 2400 version L, are listed below and shown in the foldout 8 and 9.
  • Page 201 7 Spare parts and exploded views 7.5. Spare parts - upper arm, IRB 2400/L Continued Item Qty Description Spare part no. Dimension/Note Cover with lamp unit 3HAC2743-1 Option Torx pan head roll screw 9ADA629-44 M5x12 8 Cover 3HAB4405-1 Sealing ring (without dust lip)

  • Page 204: Spare Parts - Drive Unit, Irb 2400/L

    7 Spare parts and exploded views 7.6. Spare parts - drive unit, IRB 2400/L 7.6. Spare parts - drive unit, IRB 2400/L Drive unit, IRB 2400/L, spare part list The spare parts for the drive unit, IRB 2400 /L, are listed below and shown in the foldout 10.

  • Page 206: Spare Parts - Customer Cable, Axis 4

    7 Spare parts and exploded views 7.7. Spare parts - customer cable, axis 4 7.7. Spare parts - customer cable, axis 4 Customer cable, axis 4, spare part list The spare part of the customer cable, axis 4, is listed below and shown in the following figure. Description Spare part no.

  • Page 207: Spare Parts - Limit Switch

    7 Spare parts and exploded views 7.8. Spare parts - limit switch 7.8. Spare parts - limit switch Limit switch, spare part list The spare parts for the limit switch are listed below. Item Description Spare part no. Dimension/Note Switches Holder ring Hexagon screw, button head 3HAC 0596-31...
  • Page 208 7 Spare parts and exploded views 7.8. Spare parts - limit switch 3HAC022031-001 Revision: C...

  • Page 209: Circuit Diagram

    8 Circuit diagram 8.1. Introduction 8 Circuit diagram 8.1. Introduction Overview This chapter includes the circuit diagram for the robot. Continues on next page 3HAC022031-001 Revision: C...
  • Page 210 8 Circuit diagram 8.1. Introduction Continued 3HAC022031-001 Revision: C...
  • Page 211 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 LIST OF CONTENTS Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 212 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 CONNECTION POINT LOCATIONS Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 213 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 BRAKE UNIT / SERIAL MEASUREMENT BOARD Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 214 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 MOTOR AXIS 1 - 3 Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 215 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 BRAKE UNIT / SERIAL MEASUREMENT BOARD Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 216 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 MOTOR AXIS 4 - 6, 1.5 - 10 / 16 Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 217 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 FEED- BACK AXIS 4 - 6, 1.5 10 / 16 Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 218 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 MOTOR AXIS 4 - 6, 1.8 - 5 Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 219 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 FEED - BACK AXIS 4 - 6, 1.8 - 5 Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 220 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 CUSTOMER CONNECTIONS Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 221 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 INTEGRATED WIREFEED CABLING (OPTION) Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 222 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 POS. INDICATOR AXIS 1 (OPTION) Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 223 Manipulator Circuit Diagram 3HAC 6670-3 Rev.01 EXTERNAL CONNECTIONS (OPTIONS) Product Manual IRB 2400 Sheet no. No. of Sheets 13...
  • Page 224 Index updating revolution counters 166 forces and torques on robot 40 Absolute Accuracy, calibration 161 foundation 40 attachment screws attachment screws 47 securing robot 47 orienting and securing robot 47 requirements 41 brake release unit, replacing 117 brakes gearbox axes 1-3, replacing 151 releasing manually 45 guide sleeves testing function 27...
  • Page 225 Index safety, symbols 32 scales on robot 162 oil change schedule for maintenance 67 gearbox axes 5-6 (wrist) 69 signal connectors 60 safety risks 37 SMB battery, replacing 72 oil in gearboxes, type and amount 68 SMB unit, replacing 114 operating conditions 41 special tools 179 orienting and securing robot 47...
  • Page 227 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 2400/10Irb 2400/16

Table of Contents