ABB CRB 1100 Product Manual

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ROBOTICS

Product manual

CRB 1100

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Troubleshooting

Summary of Contents for ABB CRB 1100

Page 1 ROBOTICS Product manual CRB 1100...
Page 2 Trace back information: Workspace 23B version a17 Checked in 2023-06-29 Skribenta version 5.5.019...
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, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
3.5.2 Customer connections ................Start of robot in cold environments ..............Configuring the software ..................3.7.1 Information about RobotWare and CRB 1100 ..........3.7.2 Information about Collaborative Speed Control add-in ........Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 6 5.5.1 Replacing the lower arm ................Housing, extender unit and wrist ................5.6.1 Replacing the housing ................5.6.2 Replacing the extender unit and wrist ............Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 7 Decommissioning Introduction to decommissioning ................. Environmental information .................. Scrapping of robot ..................... Reference information Introduction ...................... Applicable standards ..................Unit conversion ....................Screw joints ....................Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 8 Table of contents Weight specifications ..................Standard toolkit ....................Special tools ....................10 Spare parts 10.1 Spare part lists and illustrations ................Index Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 9: Overview Of This Manual
Product manual scope The manual covers all variants and designs of the CRB 1100. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 References Documentation referred to in the manual, is listed in the table below. Document name Document ID Product manual, spare parts - CRB 1100 3HAC078009-001 Product specification - CRB 1100 3HAC082108-001 Safety manual for robot - Manipulator and IRC5 or OmniCore con-...
Page 11 • Added information about Wrist Optimization in calibration chapter. • Added notes about installation and configuration of additional scalable I/O device. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 12 Added pin assignment on XG1 connector of SafetyIO-based laser scanner. • Updated the logical expressions for SafeMove configuration using Visual SafeMove, see Configuring pre logic on page 114. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 13: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 14 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 15: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several product models, can be illustrated with illustrations that show a different product model than the one that is described in the current manual. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 16: Network Security
ABB Ltd and its entities are not liable for damage and/or loss related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
Page 17: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.
Page 18: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 19: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 20 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 21: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 22 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 23 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 24 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 25 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 26 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 27: Robot Stopping Functions
The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - OmniCore C30 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 28: Safety During Installation And Commissioning
Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 29 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 30: Safety During Operation
Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 31: Safety During Maintenance And Repair
Make sure that protective gear there is a risk of an allergic reac- like goggles and gloves are al- tion. ways worn. Allergic reaction Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 32 See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Related information See also the safety information related to installation and operation. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 33: Emergency Release Of The Robot Axes
In an emergency situation, the brakes on a robot axis can be released manually by pushing a brake release button. How to release the brakes is described in the section: • Manually releasing the brakes on page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 34: Brake Testing
For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 35: Safety During Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 36: Safety During Decommissioning
1.8 Safety during decommissioning General See section Decommissioning on page 699. If the robot is decommissioned for storage, take extra precaution to reset safety devices to delivery status. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 37: Manipulator Description
2.1 About CRB 1100 Introduction The CRB 1100 is one of ABB Robotics latest generation of 6-axis robot, with a payload of 4 kg, designed based on industrial robot platform. It bridges the gap between industrial robots and robots designed for collaborative applications.
Page 38: Technical Data
Loads on foundation, robot The illustration shows the directions of the robots stress forces. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 39 ±710N Force z +210 ±380 N +210 ±510 N Torque xy ±180 Nm ±330 Nm Torque z ±90 Nm ±140 Nm Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 40 Motion Process Mode in the manual that de- ance frequency than scribes the controller software option, see recommended. References on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 41 Environmental information The product complies with IEC 63000. Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 42: Safety Data
ISO 10218 is warranted for the application. Safety functions and safety related data Safety functions and safety related data for CRB 1100 rely on the controller and safety laser scanners. Safety data for the controller is detailed in the product manual of the robot controller,...
Page 43: Dimensions
2 Manipulator description 2.4 Dimensions 2.4 Dimensions Main dimensions of CRB 1100-4/0.475 xx2000002545 Description Turning radius: R85 Turning radius: R109 Turning radius: R61 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 44 2 Manipulator description 2.4 Dimensions Continued Main dimensions of CRB 1100-4/0.58 xx2000002546 Description Turning radius: R85 Turning radius: R109 Turning radius: R61 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 45: Working Range
-26.4° -205° pos6 -87.6 453.4 -115° 55° pos7 -475 -90° -87.7° pos8 -430.7 126.2 -115° -87.7° pos9 188.4 488.6 113° -205° Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 46 -28.3° -205° pos6 -112.4 473.5 -115° 55° pos7 -580 -90° -88° pos8 -525.8 81.8 -115° -88° pos9 237.3 517.1 113° -205° Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 47 Default value. ±242 Maximum revolution value. The default working range for axis 6 can be exten- ded by changing parameter values in the soft- ware. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 48: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 49: Installation And Commissioning
Safety on page 17 before performing any installation work. Note Always connect the CRB 1100 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: •...
Page 50: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • Be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work. • Conform to all national and local codes.
Page 51: Risk Of Tipping/Stability
Do not change the robot position before securing it to the foundation! Transportation position This figure shows the robot in its transportation position. CRB 1100-4/0.475 45° 35° 10° xx2100000153 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 52 The robot might be positioned in a different position at delivery, due to actual configurations and options (for example DressPack). WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 53: On-Site Installation
When the robot is inverted, grasp the robot with one hand supporting at the housing and the other hand holding the base. xx2100000157 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 54 Be careful so that the robot does not bump into something while lifting and transporting. It could damage the robot. Secure the robot on a workbench according to section Orienting and securing the robot on page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 55: Lifting And Rotating A Suspended Mounted Robot
Introduction How to lift and turn the robot to a suspended position: Contact ABB for more information. How to lift and turn the robot into position for wall position: Contact ABB for more information. Product manual - CRB 1100 3HAC078007-001 Revision: J...
Page 56: Orienting And Securing The Robot
The foundation surface must be clean and un- figuration, base on page painted. CAUTION The weight of the CRB 1100 robot is 21.1 kg All lifting accessories used must be sized accord- ingly. CAUTION When the robot is put down after being lifted or transported, there is a risk of it tipping, if not properly secured.
Page 57 + 0.012 4x M12 4x M12 6 H7 6 H7 11.5 11.5 + 0.012 + 0.012 4x R16 4x R16 6 H7 6 H7 xx1800002448 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 58: Manually Releasing The Brakes
Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 59 If they are mixed up, damage can be caused to internal electrical components. xx1800002443 Use the brake releasing button as described in Releasing the brakes on page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 60: Setting The System Parameters For An Inverted Or A Tilted Robot
If the robot is mounted on a wall (rotated around the x-axis), then the robot base frame and the system parameter Gravity Alpha must be redefined. The value of Gravity Alpha should then be ±π/2 (±1.570796). Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 61 Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Wall mounted 90° 1.570796 Inverted mounting 180° 3.141593 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 62 Pos 1 Floor mounted Pos 2 Mounting angle 45° (Tilted) Pos 3 Mounting angle 90° (Wall) Pos 4 Mounting angle 180° (Suspended) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 63 The value of the system parameters that define the mounting angle must be redefined when changing the mounting angle of the robot. The parameters belong to the type Robot, in the topic Motion. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 64 3.3.4 Setting the system parameters for an inverted or a tilted robot Continued The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 65: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. See the product specification for the robot, listed in References on page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 66: Fitting Equipment On The Robot (Robot Dimensions)
3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) 3.3.6 Fitting equipment on the robot (robot dimensions) Robot dimensions Dimensions CRB 1100-4/0.475 The figure shows the dimension of the CRB 1100-4/0.475. xx2000002545 Description Turning radius: R85 Turning radius: R109...
Page 67 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued Dimensions CRB 1100-4/0.58 The figure shows the dimension of the CRB 1100-4/0.58. xx2000002546 Description Turning radius: R85 Turning radius: R109 Turning radius: R61 Attachment holes and dimensions Extra loads can be mounted on robot.
Page 68 Maximum allowed arm load depends on center of gravity of arm load and robot payload. Holes for fitting extra equipment (4x) M3 x6 (4x) M4x6 (4x) M5x10 xx1800002449 CRB 1100-4/0.475 CRB 1100-4/0.58 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 69 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued (2x) M4 (4x) M3 (2x) M4 xx1800002450 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 70 When fitting tools on the tool flange, only use screws with quality 12.9. For other equipment use suitable screws and tightening torque for your application. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 71: Installation Of Lead-Through Device
Otherwise, it will cause cabling damages. Note Two types are available to the lead-through device used with the CRB 1100, no-button-type and two-button-type. The actual delivered device type varies according to the order time. Unless otherwise stated, the instructions of installing and configuring the device are applicable to both no-button-type device and two-button-type device.
Page 72 Preparing the adapter The lead-through device is mounted to the device base and then to the robot tool flange through an adapter. Customers can use an L-shape adapter offered by ABB (option 3314-1) or design adapters according to actual requirements. During adapter design, hole dimensions on the device base and robot tool flange shall be considered.
Page 73 Tool flange standard on page Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 74 For details about the synchronization mark, see Synchronization marks and synchronization posi- tion for axes on page 657. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 75 Action Note Install the device base to the adaptor. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 3 Nm xx2000002223 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 76 Install the device base to the adaptor. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 3 Nm xx2200000763 Insert the lead-through device to the base. xx2200000764 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 77 For details about how to install the add-in and configure the lead-through functionality, see Lead-through on page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 78: Installation Of Laser Scanner
3.3.8 Installation of laser scanner Overview The safety separation technology and speed control for CRB 1100 is based on the connection and communication of one or two safety laser scanners in the robot. Laser scanner(s) provides a timely and continuous monitor on the activities within its scanning area and forms a protective field.
Page 79 1 PROFIsafe-based laser scanner (option 3051-1), with PLC connected OmniCore controller Laser Scanner blue white black brown 24V + 0V PROFIsafe PROFIsafe xx2100000160 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 80 Laser Scanner1 OmniCore controller white blue black brown PROFIsafe PROFIsafe 24V+ 0V Laser Scanner2 white blue black brown PROFIsafe 24V+ 0V xx2200000298 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 81 24V+ 0V xx2300000227 1 SafetyIO-based laser scanner (option 3051-2) Power Laser Scanner OmniCore controller white blue black brown 24V+ 0V xx2200000299 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 82 If there are additional scalable I/O devices available, install and configure the additional devices by following the detailed procedures in Application manual - Scalable I/O. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 83 Brown with green Universal output 1 White with yellow Universal output 2 Yellow with brown Voltage 0 V DC White with grey Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 84 141 RobotWare 7.6 or Configuration of two SafetyIO-base later laser scanners (RobotWare 7.6 or later) on page 146 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 85 (RobotWare 7.10 or later and OmniCore acting as Master) on page 133 Configuration of two PROFIsafe-based laser scanners (RobotWare 7.10 or later and OmniCore acting as Master) on page 137. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 86: Restricting The Working Range
Part of the casting or fixed on the casting and can not /should not be removed. Can be installed in one or more than one position, to ensure a reduced working range, or be removed to allow extended working range. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 87: Mechanically Restricting The Working Range
Only axis 1 has a replacable mechanical stop. xx1800002452 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 88: Electrical Connection
Robot cable, signals Transfers resolver data from R1.SMB and power supply to the serial measurement board. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 89 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 90 15 m, with lamp unit cabling 3HAC078069-003 CP/CS cable for CRB 1100 also includes lamp unit cabling used for communication with the lamp unit on the process hub. The cable is also designed with free ends for more I/O connections and shall always be used properly in applications.
Page 91: Customer Connections
The connector has 12 pins. Only pins 5 to 8 are available for use. Pins 1 to 4 are used for LED indicator, and pins 9 to 12 are not connected internally. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 92 Always remember to refit the protection covers after removing them. xx1900000132 CP/CS or Ethernet connector protection covers SMB connector protection cover Air hose connector protection covers Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 93: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 94: Configuring The Software
3.7 Configuring the software Overview This section is intended for guiding users to set up robot system and configure necessary software for CRB 1100. It also contains information of some customizable safety configurations. A general software configuration procedure is listed as below.
Page 95: Information About Robotware And Crb 1100
3.7.1 Information about RobotWare and CRB 1100 3.7.1 Information about RobotWare and CRB 1100 Overview CRB 1100 is designed to simplify collaborative applications. Therefore some software features work somewhat different compared with standard industrial robots. Some of them are listed in this section.
Page 96: Information About Collaborative Speed Control Add-In
10 Select Apply to confirm and save the changes. The add-in is displayed in the controller overview if it is successfully added to the controller. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 97: Lead-Through
3 Check the lead-through device setting. The device is not configured by default and the Enable Lead-through switch is unavailable for use. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 98 You can click About the versions and refer to the pictures to figure out your device type. 4 In the Installation page of the displayed window, select the installation position of the lead-through device. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 99 Device type Observe... • The ABB logo on the device is in the correct direction. No-button type • The indicator on the lead-through is in the correct relative position with the lamp unit on the process hub.
Page 100 7 Tap Apply. Enabling lead-through Use the following procedure to enable lead-through: 1 Make sure the robot is in Manual mode. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 101 You can feel if an axis reaches its end position. Do not try to force the axis beyond this position. 6 If desired, save the position. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 102 The default force threshold is 10%. xx2100000176 5 Observe the forces applied on the lead-through device in real time in the Force monitor area. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 103 Lock Z: the movement along the Z direction will be locked. • Lock XY: the movement along the X and Y directions will be locked. After selection, configured action takes effect when pressing the button. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 104: Safemove
The Context menu (...) contains functionality for loading, saving, and viewing configurations, and to reset the configuration. The functionality is described in detail in Application manual - Functional safety and SafeMove. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 105 A lozenge capsule can be modified in dimension, position, and rotation. xx2200000445 Note For the CRB 1100 and CRB 1300, the SafeMove configurator app offers the same functionality. The screenshots used in the manual can therefore show either one of the robots.
Page 106 Use this procedure when configuring SafeMove in the configurator app on FlexPendant. 1 Log in as a user with safety user grants. 2 Start the SafeMove configurator app. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 107 Use the following procedure to load and apply the template configuration to the robot controller. 1 Select Enable Edit Mode to edit the safety configuration. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 108 To modify the encapsulation, select it and modify the attributes. 4 To add or modify a zone, tap Add and Add Zone. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 109 The green dot in the 3D visualization shows where the new vertex is located. Use the arrows to change the position (index). Tap the grey Add button to place the vertex. xx2200000448 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 110 6 For supervision functions, select stop category, signal, and any other available setting applicable for the function. The functionality is described in detail in Application manual - Functional safety and SafeMove. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 111 Modify the Standstill Supervision settings The Standstill Supervision functionality is not active by default. It can be added, modified, and deactivated. The CRB 1100 has support for both category 0 stop and category 1 stop. xx2200000450 Modify the global supervision settings The global supervision functions are not connected to a specific safe zone or safe range.
Page 112 4 Turn off collision detection during validation of any tool force supervision 5 Start the validation procedure. If using protected groups in the safety configuration, only the modified parts must be validated. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 113 3 Select the check box Locked. Concluding steps After the validation is concluded, turn on the the SafeMove Assistant functionality, with the system parameter Disable SafeMove Assistant. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 114: Configuration Of Safemove Using Visual Safemove In Robotstudio
2 Click Pre Logic view in the Safe IO Configuration page. 3 Click New expression and create the following expressions. • ISH_Activate_SST • ISH_Activate_TSP • ISH_Delay_SST Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 115 DELAY(ISH_Enabler_Delay_SST,Protect- ingArea1,(ISH_AtUser_Period_ms_Until_SST / ISH_SMctrl_Frequency),ISH_Count- Delay_SST,ISH_Delayed_SST) Valid for scenarios with 2 PROFIsafe-based laser scanners connected DELAY(ISH_Enabler_Delay_SST,Protect- ingAreaSM,(ISH_AtUser_Period_ms_Until_SST / ISH_SMctrl_Frequency),ISH_Count- Delay_SST,ISH_Delayed_SST) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 116 (ROB_1) and click Capsule in the Visual SafeMove ribbon tab. 2 Set capsule properties for the robot. Parameter Value Radius (mm) Length (mm) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 117 2 Set zone properties. Parameter Value Tool Speed Supervision Pri- BASE ority Reference Task frame Botton, Top (mm) Bottom value 0.000 Top value 2100.000 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 118 1 In the Visual SafeMove ribbon tab, click Controller in the Configuration group. 2 Click Write to controller. The configurations are uploaded to the controller after the controller restarts. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 119: Speed Control
Device Device slot mapping (default) ProtectingArea ProfiSafe OmniCore_Internal WarningArea ProfiSafe OmniCore_Internal ProtectingAreaSST ProfiSafe OmniCore_Internal WarningAreaTSP ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 120 RobotStudio or the OmniCore controller. • In the RobotWare installation folder in RobotStudio: ...\DistributionPackages\ABB.RobotWare-x.x.x-xxx\RobotPackages \RobotControl_x.x.xxx\utility\service\GSDML\ • On the OmniCore Controller: ...\products\RobotControl_x.x.x\utility\service\GSDML\ Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 121 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 122 7 Create monitoring cases and assign the fields that are to be monitored to each monitoring cases in Configuration > Monitoring cases. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 123 1 Make some initial preparations. 2 Configure system parameters. 3 Set the input and output size and name of the PROFINET internal device. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 124 3 Installation and commissioning 3.7.5.1 Configuration of one PROFINET-base laser scanner (RobotWare 7.5 or earlier) Continued For CRB 1100, required settings for communication between laser scanner, PLC and OmniCore controller are predefined in the configuration file. 4 Set up safety user grants.
Page 125: Configuration Of One Profisafe-Based Laser Scanner (Robotware 7.6 Or Later And Plc Acting As Master)
OmniCore_Internal WarningArea ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable • The PROFINET device name of the controller must be set to omnicoreprofisafe. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 126 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 127 3 and 2, respectively, and for the SDO are set to 5 and 4, respectively. • Make sure the address for the SDO signal is the first address of SDO 8 bytes slot. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 128 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 129: Configuration Of Two Profisafe-Based Laser Scanners (Robotware 7.6 Or Later And Plc Acting As Master)
OmniCore_Internal WarningArea ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable • The PROFINET device name of the controller must be set to omnicoreprofisafe. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 130 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 131 Add the controller to the PLC by adding the DI 8 bytes, DO 8 bytes, SDI 8 bytes and SDO 8 bytes modules. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 132 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 133: Configuration Of One Profisafe-Based Laser Scanner (Robotware 7.10 Or Later And Omnicore Acting As Master)
The mappings are only for examples. Refer to the cut-off setting defined in the Safety Designer software and enter the actual value. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 134 The RAPID program is displayed in the right pane. b Find the parameter Scanner1 and modify its value to the user-defined laser scanner name. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 135 1 Connect the laser scanner to the PC using a network cable. See the physical connection in Connecting the laser scanner(s) on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 136 2 In the Controller tab, click Safety, then select Visual SafeMove. 3 In the Visual SafeMove window, configure SafeMove function as instructed Configuration of SafeMove using Visual SafeMove in RobotStudio on page 114. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 137: Configuration Of Two Profisafe-Based Laser Scanners
The mappings are only for examples. Refer to the cut-off setting defined in the Safety Designer software and enter the actual value. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 138 The RAPID program is displayed in the right pane. b Find the parameters Scanner1 and Scanner2, and modify their values to the user-defined laser scanner names. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 139 1 Connect the laser scanner to the controller using a network cable. See the physical connection in Connecting the laser scanner(s) on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 140 2 In the Controller tab, click Safety, then select Visual SafeMove. 3 In the Visual SafeMove window, configure SafeMove function as instructed Configuration of SafeMove using Visual SafeMove in RobotStudio on page 114. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 141: Configuration Of One Safetyio-Base Laser Scanner (Robotware 7.6 Or Later)
Value of WarningArea depends on logic AND value of ABB_Scalable_IO_0_DI3 and ABB_Scalable_IO_0_DI4. For definition of WarningArea, see Configuring the laser scanner on page 142. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 142 2 Set IP address in Configuration > Addressing. Make sure the scanner IP address is in the same network segment with the PC used for configuring the scanner. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 143 3 Connect the logic power supply to connector X4 of the scalable I/O device via pin locations PWR and GND. 4 Connect the Ethernet cable from the robot controller to connector X5. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 144 Make sure the user logged in have access grants to lock safety controller configurations, safety services and software synchronization. 2 Tap SafeMove on the home page. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 145 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 146: Configuration Of Two Safetyio-Base Laser Scanners (Robotware 7.6 Or Later)
Value of WarningArea depends on logic AND value of ABB_Scalable_IO_0_DI3, ABB_Scalable_IO_0_DI4, ABB_Scalable_IO_0_DI7 and ABB_Scalable_IO_0_DI8. For definition of WarningArea, see Configuring the laser scanner on page 147. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 147 • Make sure the scanner IP addresses are in the same network segment with the PC used for configuring the scanner. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 148 1 Make sure that the laser scanner and scalable I/O device is connected as instructed in previous configuration procedure of laser scanner. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 149 If there are additional scalable I/O devices available, install and configure the additional devices by following the detailed procedures in Application manual - Scalable I/O. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 150 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 151: Speed Control Strategies
3.7.5.8 Speed control strategies General The speed control of CRB 1100 is affected by several factors, such as, the RobotWare version, the speed setting in the FlexPendant, the speed setting in motion instruction and the SpeedRefresh value. Users in different protection fields defined for laser scanner to monitor and perform different program execution actions may result in different movement speed.
Page 152 3 Installation and commissioning 3.7.5.8 Speed control strategies Continued Users in Warning area xx2100000513 SafeMove triggered but SST/TSP not configured xx2100000514 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 153 3 Installation and commissioning 3.7.5.8 Speed control strategies Continued Strategies (RobotWare 7.6 or later) Users in Protecting area xx2200000302 Users in Warning area xx2200000303 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 154: Robot Status Indication
3 Installation and commissioning 3.7.6 Robot status indication 3.7.6 Robot status indication Description The lamp unit on process hub of CRB 1100 indicates robot status in four colors. Operators should always be aware of the indicator color and handle the situation correspondingly. Cabling The lamp unit cabling is integrated in the CP/CS cable.
Page 155 0% speed and stands still. For RobotWare 7.6 or later, the speed shown on the FlexPendant remains but the manipulator will stand still. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 156: Use Cases Of Safety Configurations
FALSE TRUE Green FALSE TRUE FALSE TRUE FALSE FALSE Yellow TRUE TRUE FALSE Cyan FALSE TRUE TRUE Purple TRUE FALSE TRUE Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 157 3 In the Controller tab, choose Visual SafeMove from the Safety group in the Configuration category. 4 In the Visual SafeMove tab, click Safe IO Configurator in the Configuration group. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 158 The speed limit can also be changed in SafeMove configurations using the following procedure: 1 Open the RobotStudio. 2 Log in the controller using the Admin account and request the write access. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 159 6 Apply the configuration to the controller by clicking Write to Controller in the Controller group in the Configuration category. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 160 6 Apply the configuration to the controller by clicking Write to Controller in the Controller group in the Configuration category. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 161: Test Run After Installation, Maintenance, Or Repair
If maintenance or repair has been done, verify the function of the part that was main- tained. Verify the application in the operating mode manual reduced speed. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
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Page 163: Maintenance
Note If the CRB 1100 is connected to power, always make sure that the CRB 1100 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.
Page 164: Maintenance Schedule And Expected Component Life
4.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the CRB 1100: • Calendar time: specified in months regardless of whether the system is running or not.
Page 165: Maintenance Schedule
Axis-1 and axis-4 timing belts can be accessed and inspected only after the axis-1 and axis-4 motors are removed. It is recommended to inspect the timing belts when replacing the motors. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 166 The battery is to be replaced at given maintenance interval or at battery low alert. vii Not needed separately if already included in the application. viii Recommended test interval is within the range 8-48 hours. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 167: Expected Component Life
Examples of "extreme usage" in regard to movement: press tending, very severe palletizing applications, major use of axis 1 movement and major use of bending backwards of axis 3. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 168: Cleaning Activities
4.3.1 Cleaning the CRB 1100 General To secure high uptime it is important that the CRB 1100 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the CRB 1100.
Page 169: Inspection Activities
Read manual label, also specifying warning labels Rating label, CE label and AbsAcc label Calibration label Required tools and equipment Visual inspection, no tools are required. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 170 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare parts on page 713. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 171: Inspecting The Robot Cabling
• the cabling to motors 1 and 2. Look for abrasions, cuts or crush damage. Replace the cabling if wear or damage is detected. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 172: Inspecting Timing Belts
4.4.3 Inspecting timing belts Location of timing belts The timing belts are located as shown in the figures. Axis Location xx1800002457 xx1800002458 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 173 4 Maintenance 4.4.3 Inspecting timing belts Continued Axis Location xx1800002459 xx1800002460 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 174 Other tools and procedures may be required if the spare part needs to be replaced. These are specified in the replacement procedure. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 175 Use a sonic tension meter to measure the Timing belt tension on page 175. timing belt tension. If the belt has no tension, adjust it! Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 176: Lubricating Activities
4.5.1 Lubricating the cable package Location of the cable package The CRB 1100 main cable package has two segments, upper and lower. Inside the swing there is a division point. The cable packages are located as shown in the figure.
Page 177 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have con- tacting area with the cable package. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 178: Replacing/Changing Activities
The battery pack is located as shown in the figure. xx1800002463 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 179 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1800003288 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 180 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002468 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 181 ESD on page Disconnect the battery cable. xx1800002469 Remove the battery pack by cutting the cable strap. xx1800002470 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 182 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 183 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
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Page 185: Repair
Note If the CRB 1100 is connected to power, always make sure that the CRB 1100 is connected to protective earth and a residual current device (RCD) before starting any repair work. For more information see: •...
Page 186: General Procedures
Check the sealing to ensure that: • The sealing is of the correct type. • There is no damage on the main lip. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 187 Mount the sealing correctly with a mounting tool. Never hammer directly on the sealing as this may result in leakage. xx2000000072 A Gap Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 188 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface. Tighten the screws evenly when fastening the flange joint.
Page 189: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 190: Cable Harness
5.3 Cable harness 5.3 Cable harness General The CRB 1100 main cable package has two segments, upper and lower. Inside the swing there is a division point. The lower cable package runs from the base and up through into the swing. The upper cable package runs from the swing, up through the lower arm, into the housing and then into the wrist.
Page 191: Replacing The Upper Cable Package
The upper cable package is located as shown in the figure. xx1800002466 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 192 Used for measuring the timing belt tension. Dynamometer Used for measuring the timing belt tension. M3x25 eye bolt Included in the special toolkit 3HAC071022-001. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 193 Preparations before removing the upper cable package Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 194 5.3.1 Replacing the upper cable package Continued Action Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB 1100-4/0.58) • Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB 1100-4/0.58) • Axis 4: 0° •...
Page 195 Snap loose and remove the female head of the connector from the connector plate. xx1800002491 Remove the swing cover. xx1800002492 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 196 Be aware of the motor cabling. The motor cannot be removed completely until the connector is xx1800003603 disconnected, as shown in following step. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 197 Snap loose and remove the female head of the connectors from the connector plate. xx1800002498 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 198 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Disconnect the air hoses from the Y-shaped con- nectors. xx1800002500 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 199 Be aware of the cabling that is attached to the cover! The cover can not be removed completely until the connectors are disconnected, as shown in following steps. xx2000002219 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 200 • J5.C1 xx2100000293 For robots with Ethernet cabling J5.C2 connector assembly tool: - Disconnect the connector J5.C2 using the tool. xx1800002948 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 201 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the wrist covers from both sides. xx1800002949 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 202 Disconnecting the axis-6 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 203 Make sure axes are well supported before remov- ing motors. Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002995 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 204 Valid for CRB 1100-4/0.475 Access the cable package locking screw on the axis-4 gearbox from the wrist and then loosen the locking screw. xx1800003031 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 205 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800003002 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 206 • • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800003005 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 207 Make sure axes are well supported before remov- ing motors. Remove the lower arm cover. xx1800003007 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 208 Pay attention not to scratch the casting or damage the pad. xx1800003604 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 209 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the housing cover. xx1800003011 Disconnect the motor connectors. • • xx1800003012 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 210 Pulling out the upper cable harness Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 211 5.3.1 Replacing the upper cable package Continued Action Note Pull out the upper cable harness from the robot in the direction shown in the figure. xx1800003015 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 212 Wrap the connectors with the masking tape. gearbox. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1800003017 xx1800003601 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 213 Surfaces to be paralleled are shown in the following figures. xx1800003019 xx1800003020 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 214 Valid for CRB 1100-4/0.58 Plug screw: 3HAC064146-001 Refit the plug screw and washer on the extender Tightening torque: 2 Nm unit. xx1800003000 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 215 Remember to refit the lower arm support and xx1800003016 swing support after the cable package is inserted to place. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 216 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 217 Check the cooling pad. Cooling pad for axis-3 and -4 mo- tors: 3HAC071021-001 Replace if damaged. xx1800003604 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 218 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003022 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 219 21.7-23.94 N (for reference tial referenced force. only) Initial referenced force for new belt: 31-34.2 N xx1900000028 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 220 Slide the connectors into the connector plate and reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx1800003005 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 221 Tightening torque: 0.6 Nm xx1800003006 Refit the connector plate. Screw: M3x12 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.4 Nm xx1800003004 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 222 Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side. xx1800003023 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 223 8.96-9.8 N (for reference only) tial referenced force. Initial referenced force for new belt: 12.8-14 xx1900000026 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 224 Note Reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx1800003025 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 225 Notice that the procedure is valid only when the lamp unit needs a replacement. Action Note Refit the lamp unit. Multi-color lamp unit (14 mm): 3HAC076495-001 xx2000002221 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 226 The air hoses with the same number connect to the same Y-shaped connector. xx1800002945 For robots with CP/CS cabling Reconnect the connector. • J5.C1 xx2100000293 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 227 The air hoses with the same number connect to the same Y-shaped connector. xx1800002500 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 228 Refitting the axis-2 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 229 Bend the motor signal cable back towards the swing support. xx1800003027 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 230 Install an M6x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000010 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 231 New belt:180-229 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 232 Reconnecting the connectors at the division point Action Note Insert the female header of the connectors to the connector plate. xx1800003029 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 233 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 234 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 235: Replacing The Lower Cable Package
The lower cable package is located as shown in the figure. xx1800002465 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 236 Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 237 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1800003288 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 238 Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are re- move from the plate. xx1800002489 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 239 Disconnect the connector. • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002495 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 241 • J2.MP3,4,5/6 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002497 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 242 Disconnecting the air hoses, CP/CS cabling and Ethernet cabling (if equipped) Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 243 Disconnecting the SMB connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 244 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J ©...
Page 245 Opening the connector interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 246 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 247 Remove the base bottom cover. xx1800003035 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx1800003057 Disconnect the earth cable. xx1800003036 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 248 Remove the female header of the J1M.BR connect- or from the connector plate. xx1800003039 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 249 Separating the cable package from the base Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 250 Pulling out the cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 251 Pull out the lower cable package from the base. xx1800003045 Remove the pulley cover from the lower cable package. xx1800003046 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 252 Action Note Refit the pulley cover to the lower cable package. xx1800003046 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 255 The cable protection tube surface is com- pletely parallel with the pulley cover at one side and with the flange at the other side. xx1800003063 xx1800003049 xx1800003050 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 256 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 257 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 258 Tightening torque: 1.2 Nm Valid for cabling with rear inter- face xx1800003034 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 259 Note Tighten the brake release button using the tool. brake release button assembly tool, included in the special toolkit 3HAC071022-001 xx1800003040 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 260 Reconnect the floor cable together with the con- Screw: M3x8 12.9 Lafre nector plate. 2C2B/FC6.9 (2 pcs) Tightening torque: 0.8 Nm xx1800003037 xx1800003036 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 261 Valid for cabling with bottom interface (option Screw: M3x8 12.9 Lafre 3309-1) 2C2B/FC6.9 (6 pcs) Refit the rear cover. Tightening torque: 1.2 Nm xx1800003057 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 262 Securing the robot to the foundation Action Note CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
Page 263 Check the cooling pad. Cooling pad for axis-1 and -2 mo- tors: 3HAC071020-001 Replace if damaged, as shown in the following step. xx1800003603 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 264 Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800002494 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 265 68.18-75.04 N (for reference tial referenced force. only) Initial referenced force for new belt: 97.4-107.2 N xx1900000029 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 266 Remove the adjustment screw from the motor. xx1900000010 Reconnect the connector. • See the number markings on the connectors for help to find the corresponding connector. xx1800002495 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 267 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.8 Nm xx1800002489 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 268 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 269: Replacing The Smb Unit
The SMB unit is located as shown in the figure. xx1800002464 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 270 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 271 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 272 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 273 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 274 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 275 • SMB.P7 • SMB.J1 • SMB.J2 See the number markings on the connectors for help to find the corresponding connector. xx1800002468 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 276 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 277: Swing And Base
The base is located as shown in the figure. xx1800002472 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 278 Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 279 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1800003288 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 280 Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are re- move from the plate. xx1800002489 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 281 Disconnect the connector. • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002495 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 283 • J2.MP3,4,5/6 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002497 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 284 Disconnecting the air hoses, CP/CS cabling and Ethernet cabling (if equipped) Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 285 Putting the robot on its side Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 286 5.4.1 Replacing the base Continued Action Note CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Loosen the robot from the foundation by removing the foundation attachment screws and put the robot on its side.
Page 287 Opening the connector interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 288 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 289 Remove the base bottom cover. xx1800003035 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx1800003057 Disconnect the earth cable. xx1800003036 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 290 Remove the female header of the J1M.BR connect- or from the connector plate. xx1800003039 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 291 Separating the cable package from the base Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 292 Pulling out the cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 293 Removing the axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 294 Pay attention not to scratch the casting or damage the pad. xx1800003602 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 295 Separating the base from the swing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 296 Separate the base from the swing. CAUTION The axis-1 mechanical stop is accessible now. Put it aside for later refitting. xx1800003070 xx1800003071 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 297 (A) on the swing. Make sure the mechanical stop step pointed in the figure is fa- cing the swing when putting. xx1800003071 xx1800003619 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 298 Refitting the axis-1 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 300 Pay attention to the force application direction. xx1900000041 Secure the motor with the screws. Tightening torque: 3 Nm Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 301 Action Note Refit the pulley cover to the lower cable package. xx1800003046 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 304 The cable protection tube surface is com- pletely parallel with the pulley cover at one side and with the flange at the other side. xx1800003063 xx1800003049 xx1800003050 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 305 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 306 Refit the SMB cover to the base. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 1.2 Nm xx1800002467 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 307 Reconnect the connectors. • J1M.BR • • See the number markings on the connectors for help to find the corresponding connector. xx1800003054 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 308 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 309 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 310 Tightening torque: 1.2 Nm Valid for cabling with rear inter- face xx1800003034 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 311 Securing the robot to the foundation Action Note CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
Page 312 Check the cooling pad. Cooling pad for axis-1 and -2 mo- tors: 3HAC071020-001 Replace if damaged, as shown in the following step. xx1800003603 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 313 Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800002494 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 314 68.18-75.04 N (for reference tial referenced force. only) Initial referenced force for new belt: 97.4-107.2 N xx1900000029 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 315 Remove the adjustment screw from the motor. xx1900000010 Reconnect the connector. • See the number markings on the connectors for help to find the corresponding connector. xx1800002495 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 316 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.8 Nm xx1800002489 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 317 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 318: Replacing The Swing
The swing is located as shown in the figure. xx1800002473 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 319 Included in the special toolkit 3HAC071022-001. Used to remove and refit the brake release button. Required consumables Consumable Article number Note Cable straps Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 320 Preparations before removing the swing Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 321 Make sure axes are well supported before remov- ing motors. Remove the swing support cover. xx1800002488 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 322 Snap loose and remove the female head of the connector from the connector plate. xx1800002491 Remove the swing cover. xx1800002492 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 323 Be aware of the motor cabling. The motor cannot be removed completely until the connector is xx1800003603 disconnected, as shown in following step. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 324 Disconnecting the connectors at the division point Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 325 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800002499 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 326 The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 327 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation.
Page 328 Opening the connector interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 329 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 330 Remove the base bottom cover. xx1800003035 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx1800003057 Disconnect the earth cable. xx1800003036 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 331 Remove the female header of the J1M.BR connect- or from the connector plate. xx1800003039 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 332 Separating the cable package from the base Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 333 Pulling out the cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 334 Removing the axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 335 Pay attention not to scratch the casting or damage the pad. xx1800003602 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 336 Separating the base from the swing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 337 Separate the base from the swing. CAUTION The axis-1 mechanical stop is accessible now. Put it aside for later refitting. xx1800003070 xx1800003071 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 338 Separating the swing from the lower arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 339 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002192 Separate the swing from the lower arm.
Page 340 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002192 Route the cable package through the swing sup- port.
Page 341 Placing the axis-1 mechanical stop Action Note Check the axis-1 mechanical stop. Mechanical stop, axis 1: 3HAC061947-001 Replace if damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 342 Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (13 pcs) Tightening torque: 4.4 Nm Note Pay attention to the screw and washer location. xx1800003069 xx1800003068 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 343 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley. xx1800003085 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 344 Do not tighten the screws yet. xx1800003065 Adjusting the axis-1 timing belt tension Action Note Use a handheld dynamometer hooking to the motor. xx1900000040 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 345 Action Note Refit the pulley cover to the lower cable package. xx1800003046 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 348 The cable protection tube surface is com- pletely parallel with the pulley cover at one side and with the flange at the other side. xx1800003063 xx1800003049 xx1800003050 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 349 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 350 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 351 Tightening torque: 1.2 Nm Valid for cabling with rear inter- face xx1800003034 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 352 Reconnect the connectors. • J1M.BR • • See the number markings on the connectors for help to find the corresponding connector. xx1800003054 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 353 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 354 Securing the robot to the foundation Action Note CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
Page 355 Securing the cable package to the swing Action Note Refit the cable bracket. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.8 Nm xx1800002499 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 356 Bend the motor signal cable back towards the swing support. xx1800003027 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 357 Install an M6x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000010 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 358 New belt:180-229 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 359 Reconnecting the connectors at the division point Action Note Insert the female header of the connectors to the connector plate. xx1800003029 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 360 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 361 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 362: Lower Arm
The lower arm is located as shown in the figure. xx1800002474 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Lower arm (CRB 1100-4/0.58)
Page 363 Dynamometer Used for measuring the timing belt tension. Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 364 Preparations before removing the lower arm Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 365 5.5.1 Replacing the lower arm Continued Action Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB 1100-4/0.58) • Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB 1100-4/0.58) • Axis 4: 0° •...
Page 366 Snap loose and remove the female head of the connector from the connector plate. xx1800002491 Remove the swing cover. xx1800002492 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 367 Be aware of the motor cabling. The motor cannot be removed completely until the connector is xx1800003603 disconnected, as shown in following step. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 368 Snap loose and remove the female head of the connectors from the connector plate. xx1800002498 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 369 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Disconnect the air hoses from the Y-shaped con- nectors. xx1800002500 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 370 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800003002 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 371 • • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800003005 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 372 Make sure axes are well supported before remov- ing motors. Remove the lower arm cover. xx1800003007 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 373 Pay attention not to scratch the casting or damage the pad. xx1800003604 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 374 Separating the swing from the lower arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 375 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002203 Separate the swing from the lower arm.
Page 376 Pull out the upper cable harness upwards from the lower arm support. xx1800003086 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 377 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002190 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J ©...
Page 378 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002190 Securing the lower arm support...
Page 379 Note Refit the axis-2 gearbox. xx1800003083 Secure with screws. Screw: M3x30 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 1.9 Nm xx1800003082 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 380 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002203 Securing the swing support Action...
Page 381 Check the cooling pad. Cooling pad for axis-3 and -4 mo- tors: 3HAC071021-001 Replace if damaged. xx1800003604 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 382 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003022 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 383 21.7-23.94 N (for reference tial referenced force. only) Initial referenced force for new belt: 31-34.2 N xx1900000028 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 384 Slide the connectors into the connector plate and reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx1800003005 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 385 Tightening torque: 0.6 Nm xx1800003006 Refit the connector plate. Screw: M3x12 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.4 Nm xx1800003004 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 386 Reconnect the connectors. • J2.C1 • J2.C2 See the number markings on the connectors for help to find the corresponding connector. xx1800002501 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 387 Check the cooling pad. Cooling pad for axis-1 and -2 mo- tors: 3HAC071020-001 Replace if damaged, as shown in the following step. xx1800003603 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 388 Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800002494 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 389 68.18-75.04 N (for reference tial referenced force. only) Initial referenced force for new belt: 97.4-107.2 N xx1900000029 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 390 Remove the adjustment screw from the motor. xx1900000010 Reconnect the connector. • See the number markings on the connectors for help to find the corresponding connector. xx1800002495 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 391 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.8 Nm xx1800002489 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 392 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 393: Housing, Extender Unit And Wrist
The housing is located as shown in the figure. xx1800002475 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 394 Note Cable straps Grease 3HAC029132-001 FM 222 Grease Castrol Molub. Alloy 777-1 NG Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 395 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB 1100-4/0.58) • Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB 1100-4/0.58) • Axis 4: 0°...
Page 396 The cover can not be removed completely until the connectors are disconnected, as shown in following steps. xx2000002219 Disconnect the air hoses. xx1800002945 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 397 Removing the wrist covers Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 398 Access the connector FB5 from the process hub and disconnect the connector. xx1800002950 Disconnect the connector. • xx1800002993 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 399 Make sure axes are well supported before remov- ing motors. Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002995 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 400 Valid for CRB 1100-4/0.475 Access the cable package locking screw on the axis-4 gearbox from the wrist and then loosen the locking screw. xx1800003031 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 401 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the housing cover. xx1800003011 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 402 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800003013 xx1800003014 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 403 Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing motors. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 404 Pay attention not to scratch the casting or damage the pad. xx1800003605 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 405 Make sure axes are well supported before loosening timing belts. Remove the pulley cover. xx1800003097 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 406 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002191 Valid for CRB 1100-4/0.475 Separate the wrist from the housing.
Page 407 The connector plate cannot be removed completely until the connectors are re- move from the plate, as shown in following step. xx1800003004 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 408 If the lower arm support is hard to loosen from the housing, use a plastic hammer to knock on the lower arm support lightly. xx1800003088 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 409 Remove the lower arm cover. xx1800003007 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003008 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 410 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002190 Separate the lower arm from the housing.
Page 411 Make sure axes are well supported before remov- ing gearboxes. Remove the screws on the labyrinth sealing ring. xx1900001425 Remove the labyrinth sealing ring lightly and evenly. xx1900001417 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 412 Refitting the housing Use these procedures to refit the housing. Refitting the axis-3 gearbox Action Note Refit the axis-3 gearbox. xx1800003285 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 413 Refit the labyrinth sealing ring lightly and evenly. Note Make sure the labyrinth sealing ring is well fitted to the axis-3 gearbox without any deflection. xx1900001417 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 414 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002190 Securing the lower arm support...
Page 415 Install an M4x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000009 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 416 New belt: 113-143 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 417 Refit the cable bracket. Screw: M2.5x6 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.6 Nm xx1800003006 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 418 Refit the the wrist to the housing. xx1800003075 Valid for CRB 1100-4/0.58 Refit the extender unit and wrist to the housing. xx1800003100 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 419 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002191 Refitting the axis-4 timing belt and pulley cover...
Page 420 Use the motor fitting tool to fix the timing belt. axis-4 motor fitting tool, included in the special toolkit 3HAC071022- 001. xx1900000044 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 421 Screw: M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Washer, 3HAC064765-001 (3 pcs) Note Do not tighten the screws yet. xx1800003095 Remove the motor fitting tool. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 422 Fit an M3x25 eye bolt o the screw hole. xx1900000037 Use a handheld dynamometer hooking to the eye bolt. xx1900000038 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 423 Tightening torque: 1.4 Nm xx1800003094 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001 below the housing. Tightening torque: 2 Nm Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 424 Wrap the connectors with the masking tape. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1800003017 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 425 Surfaces to be paralleled are shown in the following figures. xx1800003019 xx1800003020 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 426 Valid for CRB 1100-4/0.58 Plug screw: 3HAC064146-001 Refit the plug screw and washer on the extender Tightening torque: 2 Nm unit. xx1800003000 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 427 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 428 Refitting the axis-6 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 429 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003024 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 430 New belt:90-114 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 431 If the cables are routed and secured incorrectly the cables can be damaged. Insert the cabling and connectors into the wrist. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 432 The air hoses with the same number connect to the same Y-shaped connector. xx1800002945 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 433 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 434 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 435: Replacing The Extender Unit And Wrist
5.6.2 Replacing the extender unit and wrist 5.6.2 Replacing the extender unit and wrist Location of the extender unit and wrist The CRB 1100-4/0.58 has an extender unit connecting the housing and wrist, which is located as shown in the figure. xx1800002476...
Page 436 The wrist is located as shown in the figure. xx1800002477 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 437 Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 438 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB 1100-4/0.58) • Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB 1100-4/0.58) • Axis 4: 0°...
Page 439 The cover can not be removed completely until the connectors are disconnected, as shown in following steps. xx2000002219 Disconnect the air hoses. xx1800002945 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 440 Removing the wrist covers Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 441 Access the connector FB5 from the process hub and disconnect the connector. xx1800002950 Disconnect the connector. • xx1800002993 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 442 Make sure axes are well supported before remov- ing motors. Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002995 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 443 Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing motors. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 444 Remove the screws and washers. xx1800003294 Carefully lift out the motor. Remove the timing belt from its groove on the motor. xx1800003295 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 446 Separating the upper cable package from the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 447 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the lower arm support cover. xx1800003092 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 448 Make sure axes are well supported before remov- ing motors. Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003094 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 449 Removing the pulley cover and axis-4 timing belt Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 450 Separating the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 451 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002191 Valid for CRB 1100-4/0.475 Separate the wrist from the housing.
Page 452 Remove the screws. xx1800003300 Pull out the gearbox. xx1800003310 Separating the extender unit and wrist Notice that this procedure is valid for CRB 1100-4/0.58. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off.
Page 453 Refitting the extender unit and wrist Use these procedures to refit the extender unit and wrist. Refitting the extender unit to the wrist Notice that this procedure is valid for CRB 1100-4/0.58. Action Note Align the parallel pin on the extender unit with the Parallel pin: 3HAC050369-032 pin hole on the wrist.
Page 454 Action Note Refit the extender unit to the wrist. Screw: M3x16 12.9 Lafre 2C2B/FC6.9 (16 pcs) Tightening torque: 2 Nm xx1800003311 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 455 Valid for CRB 1100-4/0.475 xx1800003313 Valid for CRB 1100-4/0.58 xx1800003312 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 456 Refit the the wrist to the housing. xx1800003075 Valid for CRB 1100-4/0.58 Refit the extender unit and wrist to the housing. xx1800003100 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 457 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002191 Refitting the axis-4 timing belt and pulley cover...
Page 458 Use the motor fitting tool to fix the timing belt. axis-4 motor fitting tool, included in the special toolkit 3HAC071022- 001. xx1900000044 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 459 Screw: M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Washer, 3HAC064765-001 (3 pcs) Note Do not tighten the screws yet. xx1800003095 Remove the motor fitting tool. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 460 Fit an M3x25 eye bolt o the screw hole. xx1900000037 Use a handheld dynamometer hooking to the eye bolt. xx1900000038 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 461 Tightening torque: 1.4 Nm xx1800003094 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001 below the housing. Tightening torque: 2 Nm Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 462 Wrap the connectors with the masking tape. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1800003017 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 463 Surfaces to be paralleled are shown in the following figures. xx1800003019 xx1800003020 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 464 Valid for CRB 1100-4/0.58 Plug screw: 3HAC064146-001 Refit the plug screw and washer on the extender Tightening torque: 2 Nm unit. xx1800003000 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 465 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 466 Refitting the axis-5 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 467 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003292 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 468 New belt: 167-213 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 469 Refit the screws and washers. Screw: M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Note Do not tighten the screws yet. xx1800002996 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 470 Initial referenced force for new belt: 12.8-14 xx1900000026 Secure the motor with the screws. Tightening torque: 1.4 Nm xx1800002995 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 471 If the cables are routed and secured incorrectly the cables can be damaged. Insert the cabling and connectors into the wrist. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 472 The air hoses with the same number connect to the same Y-shaped connector. xx1800002945 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 473 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 474 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 475: Motors
The axis-1 motor is located as shown in the figure. xx1800002482 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 476 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 477 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 478 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation.
Page 479 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 480 Disconnecting axis-1 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 481 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800003042 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 482 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003064 Remove the screws and washers. xx1800003065 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 483 Check the cooling pad. Cooling pad for axis-1 and -2 mo- tors: 3HAC071020-001 Replace if damaged. xx1800003602 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 484 Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800003065 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 485 Securing the lower cable package to the base Action Note Refit the cable bracket. Screw: M2.5x6 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.6 Nm xx1800003042 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 486 Valid for cabling with bottom interface (option Screw: M3x8 Steel 8.8-A2F (7 pcs) 3309-1) Tightening torque: 1.2 Nm Refit the base adapter. xx1800003056 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 487 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 488 Securing the robot to the foundation Action Note CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
Page 489 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 490: Replacing The Axis-2 Motor
The axis-2 motor is located as shown in the figure. xx1800002483 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 491 If no previous reference values exist, and routine on page 664. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 492 Removing the axis-2 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 493 • J2.FB2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002490 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 494 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002493 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 495 Removing the cooling pad Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 496 Refitting the axis-2 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 497 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003028 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 498 Initial referenced force for new belt: 97.4-107.2 N xx1900000029 Secure the motor with the screws. Tightening torque: 3.5 Nm xx1800002493 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 499 Reconnecting the connector J2.FB2 Action Note Insert the female header of the J2.FB2 connector to the connector plate. xx1800002491 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 500 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 501 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 502: Replacing The Axis-3 Motor
The axis-3 motor is located as shown in the figure. xx1800002484 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 503 If no previous reference values exist, and routine on page 664. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 504 Disconnecting the axis-3 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 505 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800003005 Remove the cable bracket. xx1800003006 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 506 Remove the lower arm cover. xx1800003007 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003008 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 507 Pay attention not to scratch the casting or damage the pad. xx1800003604 Remove the timing belt from its groove on the motor. xx1800003010 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 508 Orient the motor correctly and fit it into the lower Motor orientation: orient the motor arm. according to the figure below, in regard to the encircled motor con- nector. xx1800003021 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 509 Install an M4x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000009 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 510 New belt:113-143 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 511 Refit the cable bracket. Screw: M2.5x6 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.6 Nm xx1800003006 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 512 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 513: Replacing The Axis-4 Motor
The xx is located as shown in the figure. xx1800002485 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 514 If no previous reference values exist, and routine on page 664. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 515 Disconnecting the axis-4 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 516 Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing motors. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 517 Pay attention not to scratch the casting or damage the pad. xx1800003605 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 518 Check the cooling pad. Cooling pad for axis-3 and -4 mo- tors: 3HAC071021-001 Replace if damaged. xx1800003605 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 519 Make sure the motor flange does not press on the timing belt. xx1800003287 Install the timing belt to the motor pulley. xx1800003617 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 520 Action Note Remove the screw and washer below the housing. xx1900000036 Fit an M3x25 eye bolt o the screw hole. xx1900000037 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 521 Tightening torque: 1.4 Nm xx1800003094 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001 below the housing. Tightening torque: 2 Nm Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 522 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 523 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 524: Replacing The Axis-5 Motor
The axis-5 motor is located as shown in the figure. xx1800002486 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 525 If no previous reference values exist, and routine on page 664. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 526 Opening the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 527 Disconnecting the axis-5 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 528 Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing motors. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 529 Remove the screws and washers. xx1800003291 Carefully lift out the motor. Remove the timing belt from its groove on the motor. xx1800003292 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 530 Refit the screws and washers. Screw: M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Note Do not tighten the screws yet. xx1800003291 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 531 13.58-14.84 N (for reference tial referenced force. only) Initial referenced force for new belt: 19.4-21.2 N xx1900000027 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 532 Note Reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx1800003025 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 533 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 534 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 535: Replacing The Axis-6 Motor
The xx is located as shown in the figure. xx1800002487 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 536 If no previous reference values exist, and routine on page 664. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 537 Opening the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 538 Disconnecting the axis-6 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 539 Make sure axes are well supported before remov- ing motors. Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002995 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 540 Refitting the axis-6 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 541 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003024 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 542 New belt:90-114 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 543 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 544 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 545: Gearboxes
The axis-1 gearbox is located as shown in the figure. xx1800002478 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 546 Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 547 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1800003288 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 548 Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are re- move from the plate. xx1800002489 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 549 Disconnect the connector. • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002495 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 551 • J2.MP3,4,5/6 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002497 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 552 Disconnecting the air hoses, CP/CS cabling and Ethernet cabling (if equipped) Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 553 Putting the robot on its side Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 554 5.8.1 Replacing the axis-1 gearbox Continued Action Note CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Loosen the robot from the foundation by removing the foundation attachment screws and put the robot on its side.
Page 555 Opening the connector interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 556 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 557 Remove the base bottom cover. xx1800003035 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx1800003057 Disconnect the earth cable. xx1800003036 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 558 Remove the female header of the J1M.BR connect- or from the connector plate. xx1800003039 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 559 Separating the cable package from the base Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 560 Pulling out the cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 561 Removing the axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 562 Pay attention not to scratch the casting or damage the pad. xx1800003602 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 563 Separating the base from the swing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 564 Separate the base from the swing. CAUTION The axis-1 mechanical stop is accessible now. Put it aside for later refitting. xx1800003070 xx1800003071 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 565 Make sure axes are well supported before remov- ing gearboxes. Remove the screws. xx1800003073 Pull out the gearbox. xx1800003074 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 566 Placing the axis-1 mechanical stop Action Note Check the axis-1 mechanical stop. Mechanical stop, axis 1: 3HAC061947-001 Replace if damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 567 Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (13 pcs) Tightening torque: 4.4 Nm Note Pay attention to the screw and washer location. xx1800003069 xx1800003068 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 568 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley. xx1800003085 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 569 Do not tighten the screws yet. xx1800003065 Adjusting the axis-1 timing belt tension Action Note Use a handheld dynamometer hooking to the motor. xx1900000040 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 570 Action Note Refit the pulley cover to the lower cable package. xx1800003046 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 573 The cable protection tube surface is com- pletely parallel with the pulley cover at one side and with the flange at the other side. xx1800003063 xx1800003049 xx1800003050 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 574 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 575 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 576 Tightening torque: 1.2 Nm Valid for cabling with rear inter- face xx1800003034 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 577 Reconnect the connectors. • J1M.BR • • See the number markings on the connectors for help to find the corresponding connector. xx1800003054 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 578 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 579 Securing the robot to the foundation Action Note CAUTION The CRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
Page 580 Securing the cable package to the swing Action Note Refit the cable bracket. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.8 Nm xx1800002499 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 581 Bend the motor signal cable back towards the swing support. xx1800003027 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 582 Install an M6x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000010 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 583 New belt:180-229 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 584 Reconnecting the connectors at the division point Action Note Insert the female header of the connectors to the connector plate. xx1800003029 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 585 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 586 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 587: Replacing The Axis-2 Gearbox
The axis-2 gearbox is located as shown in the figure. xx1800002479 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 588 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 589 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB 1100-4/0.58) • Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB 1100-4/0.58) • Axis 4: 0°...
Page 590 • J2.FB2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002490 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 591 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002493 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 592 Separating the upper cable harness from the axis-2 gearbox Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 593 Separating the swing from the lower arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 594 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002203 Separate the swing from the lower arm.
Page 595 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable block from the gearbox. xx1800003084 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 596 Screw: M2.5x6 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.6 Nm xx1800003084 Refitting the axis-2 gearbox Action Note Refit the axis-2 gearbox. xx1800003083 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 597 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002203 Securing the swing support Action...
Page 598 Refitting the axis-2 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 599 Bend the motor signal cable back towards the swing support. xx1800003027 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 600 Install an M6x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000010 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 601 New belt:180-229 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 602 Reconnecting the connector at the division point Action Note Insert the female header of the connector to the connector plate. xx1800002491 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 603 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 604 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 605: Replacing The Axis-3 Gearbox
The axis-3 gearbox is located as shown in the figure. xx1800002480 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 606 Castrol Molub. Alloy 777-1 NG Used to lubricate bearings on the swing support and lower arm support. Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 607 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB 1100-4/0.58) • Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB 1100-4/0.58) • Axis 4: 0°...
Page 608 The connector plate cannot be removed completely until the connectors are re- move from the plate, as shown in following step. xx1800003004 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 609 CAUTION The support cannot be removed completely. Make sure the hanging support will not wear or damage xx1800003286 the cable harness. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 610 Remove the lower arm cover. xx1800003007 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003008 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 611 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002190 Separate the lower arm from the housing.
Page 612 Make sure axes are well supported before remov- ing gearboxes. Remove the screws on the labyrinth sealing ring. xx1900001425 Remove the labyrinth sealing ring lightly and evenly. xx1900001417 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 613 Refitting the gearbox Use these procedures to refit the axis-3 gearbox. Refitting the axis-3 gearbox Action Note Refit the axis-3 gearbox. xx1800003285 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 614 Refit the labyrinth sealing ring lightly and evenly. Note Make sure the labyrinth sealing ring is well fitted to the axis-3 gearbox without any deflection. xx1900001417 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 615 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002190 Securing the lower arm support...
Page 616 Install an M4x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000009 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 617 New belt: 113-143 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 618 Refit the cable bracket. Screw: M2.5x6 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.6 Nm xx1800003006 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 619 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 620: Replacing The Axis-4 Gearbox
The axis-4 gearbox is located as shown in the figure. xx1800002481 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the CRB 1100 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 621 Used to refit the axis-4 motor. Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 622 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB 1100-4/0.58) • Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB 1100-4/0.58) • Axis 4: 0°...
Page 623 The cover can not be removed completely until the connectors are disconnected, as shown in following steps. xx2000002219 Disconnect the air hoses. xx1800002945 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 624 Removing the wrist covers Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 625 Access the connector FB5 from the process hub and disconnect the connector. xx1800002950 Disconnect the connector. • xx1800002993 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 626 Make sure axes are well supported before remov- ing motors. Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002995 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 627 Valid for CRB 1100-4/0.475 Access the cable package locking screw on the axis-4 gearbox from the wrist and then loosen the locking screw. xx1800003031 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 628 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the housing cover. xx1800003011 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 629 Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing motors. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 630 Pay attention not to scratch the casting or damage the pad. xx1800003605 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 631 Make sure axes are well supported before loosening timing belts. Remove the pulley cover. xx1800003097 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 632 Note Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002191 Valid for CRB 1100-4/0.475 Separate the wrist from the housing.
Page 633 Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing gearboxes. Remove the screws. xx1800003300 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 634 5 Repair 5.8.4 Replacing the axis-4 gearbox Continued Action Note Pull out the gearbox. xx1800003310 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 635 Valid for CRB 1100-4/0.475 xx1800003313 Valid for CRB 1100-4/0.58 xx1800003312 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 636 Refit the the wrist to the housing. xx1800003075 Valid for CRB 1100-4/0.58 Refit the extender unit and wrist to the housing. xx1800003100 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 637 Some robots may be fitted with separate screws and washers. During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002191 Refitting the axis-4 timing belt and pulley cover...
Page 638 Use the motor fitting tool to fix the timing belt. axis-4 motor fitting tool, included in the special toolkit 3HAC071022- 001. xx1900000044 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 639 Screw: M3x12 12.9 Lafre 2C2B/FC6.9 (3 pcs) Washer, 3HAC064765-001 (3 pcs) Note Do not tighten the screws yet. xx1800003095 Remove the motor fitting tool. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 640 Fit an M3x25 eye bolt o the screw hole. xx1900000037 Use a handheld dynamometer hooking to the eye bolt. xx1900000038 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 641 Tightening torque: 1.4 Nm xx1800003094 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001 below the housing. Tightening torque: 2 Nm Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 642 Wrap the connectors with the masking tape. gearbox. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1800003017 xx1800003601 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 643 Surfaces to be paralleled are shown in the following figures. xx1800003019 xx1800003020 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 644 Valid for CRB 1100-4/0.58 Plug screw: 3HAC064146-001 Refit the plug screw and washer on the extender Tightening torque: 2 Nm unit. xx1800003000 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 645 Refitting the axis-6 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 646 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003024 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 647 New belt:90-114 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 648 If the cables are routed and secured incorrectly the cables can be damaged. Insert the cabling and connectors into the wrist. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 649 The air hoses with the same number connect to the same Y-shaped connector. xx1800002945 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 650 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 651 DANGER Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 161. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 652 This page is intentionally left blank...
Page 653: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 654: Calibration Methods
Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of CRB 1100. It is the recommended method in order to achieve proper performance. The following routines are available for the Axis Calibration method: •...
Page 655 References Article numbers for the calibration tools are listed in the section Special tools on page 711. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 656: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 657: Synchronization Marks And Axis Movement Directions
Before installing a tool on the tool flange, make sure a visible mark has been made to the tool at the corresponding position. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 658: Calibration Movement Directions For All Axes
Positive directions are shown in the graphic below. Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below. Manual movement directions xx1800002456 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 659: Updating Revolution Counters
Use the following procedure to check and correct the axis 4 position. Action Note Remove the housing cover. xx1800003011 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 660 Jog the axis 4 anti-clockwise (with the operator facing the rear) until the cable harness is in vertic- al state. 0° 60° 120° 180° 300° 240° xx1800003318 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 661 At delivery the manipulator is in the correct position. Do NOT rotate axis 4 at power up before the revolution counters are updated. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 662 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 682. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 663: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 664 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 665 SafeMove. How to calibrate a suspended or wall mounted robot The CRB 1100 is fine calibrated floor standing in factory, prior to shipping. To calibrate a suspended or wall mounted robot, reference calibration could be used.
Page 666: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 667 If including the tool flange calibration tool in a local periodic check system, the following measures should be checked. • Outer diameter within Ø5g5 mm. • Straightness within 0.005 mm. xx1600001142 Outer diameter Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 668: Installation Locations For The Calibration Tools
For axis 6 there is only one bushing, the second calibration tool is installed at the mounting flange of the turning disk. xx1800003320 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 669 Replace damaged parts with new. Spare part Article number Note Protective plug for bushing 3HAC059556-001 Replace if damaged or missing. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 670 3HAC059557-001 Used with protection type Clean Room. Clean Room Replace if damaged or missing. Calibration pin cover, 6 mm 3HAC061926-001 Replace if damaged or missing. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 671: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 672 Use this procedure to start the Axis Calibration routine on the FlexPendant. Action Note Tap the calibration icon and enter the calibration main page. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 673 For RobotWare 7, the mechanical unit page is displayed only if there is more than one mechan- ical unit available. The calibration method used at ABB factory for The FlexPendant will give all inform- each axis is shown, as well as calibration method ation needed to proceed with Axis used for the robot during last field calibration.
Page 674 Unrestricted in the FlexPendant window. Calibration tools in contact Axis 1 Axis 2 xx1900000114 xx1900000113 Axis 3 Axis 4 xx1900000115 xx1900000116 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 675 Axis Calibration routine. When a warning message is displayed, tap Acknowledge to confirm the unsynchronized state and continue Axis Calibration procedure. CAUTION SafeMove must be synchronized after the calibration is completed. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 676 If the standard calibration data for axes 4, 5 or 6 Calibrating with Wrist Optimiz- should be updated with wrist optimization, run the ation method on page 679. calibration routine Wrist Optimization. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 677: Reference Calibration
(step 5, see Brief introduction to Reference Calibration on page 677). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 678 10 Check again against the verification position. 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 679: Calibrating With Wrist Optimization Method
3 Improved calibration data to the wrist axes is identified and presented. 4 Optimized positions for the wrist axes are presented. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 680 WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 681: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on one side of the base. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 682: Checking The Synchronization Position
If they do not, up- ization position for axes on page 657 date the revolution counters. Updating revolution counters on page 659. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 683: Troubleshooting
Check: been installed • the configuration files • connectors • options and their configuration • changes in the robot working space/movements. Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 684 The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 685: Oil And Grease Stains On Motors And Gearboxes
"cooling periods" into the your local ABB representative. application. • Overpressure created inside gearbox. Inspect all sealings and gaskets between motor and gearbox. Replace broken parts. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 686: Mechanical Noise Or Dissonance
Make sure the bearings are fitted correctly. Tighten the screws if a heat sink, fan, or metal sheet is loose. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 687: Manipulator Collapses On Power Down
Remove the motor from the gearbox to in- If found faulty, the motor must be replaced spect it from the drive side. as a complete unit. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 688: Motor Temperature Too High
The ways could be but not limited to op- tor utilization. timizing robot movement cycle, adjusting acc, dec as well as external force, adding wait time, and introducing alternative path/RAPID, etc. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 689: Communication Failure Between Profisafe-Based Laser Scanner, Plc, And Controller
2 In the Controller tab page, choose Communication from the Configuration group. 3 Select Firewall Manager in the Type pane. 4 Set Enable on Public Network to Yes for the network service ProfiNet. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 690: Communication Failure Between Plc And Controller
Configuration group. 3 Check the Safe I/O configurations. For robots running RobotWare 7.5 or earlier, the following signals can be observed. xx2100000511 Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 691 5 Go back to the Visual SafeMove window and write the SafeMove configurations to the controller again. You will observe the signals and the communication is correctly set up. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 692: Communication Failure Between Scalable I/O Device And Controller
5 Go back to the Visual SafeMove window and write the SafeMove configurations to the controller again. You will observe the signals and the communication is correctly set up. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 693: Errors Related To Stopped Background Task T_Swifti_Led
Configuration area and select CabinetIO from the drop-down list. This will update the unknown device to CabinetIO. 6 Tap Apply. 7 Restart the controller. The system works normally. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 694: Unable To Change Speed Value In Flexpendant
Set speed value is still valid. Recommended actions 1 In the FlexPendant, tap I/O in the main page. 2 Reset the StartInProtecting DO. The speed limitation will be released. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 695: Movement In Safe Area Not In Full Speed Or At Zero Speed
Reset the program pointer and start the program in the Safe area again. • Enter the Warning area but not trigger the TSP supervision violation and then back to the Safe area again. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 696: Unable To Remove Or Reselect Installed Options In Collaborative Speed Control Add-In
4 Reset the RAPID programs and parameters in RobotStudio and restart the controller. 5 Load the template SafeMove configuration file using the SafeMove configurator app on FlexPendant. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 697: Unexpected Robot Movement When Starting The Program In Protecting Area
Reset the template SafeMove configuration file to factory setting and then load the configuration file provided with the Collaborative Speed Control add-in. See detailed procedures in The SafeMove configurator app on FlexPendant on page 104. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
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Page 699: Decommissioning
See also Environmental information on page 700. Transportation Prepare the robot or parts before transport, this to avoid hazards. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 700: Environmental Information
8.2 Environmental information 8.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
Page 701 China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of CRB 1100 according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ".
Page 702: Scrapping Of Robot
• A used robot does not have the same performance as on delivery. Springs, brakes, bearings, and other parts might be worn or broken. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 703: Reference Information
9.1 Introduction 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 704: Applicable Standards
Industrial robots and robot Systems - General safety require- ments EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus- trial robots — Part 1: Robots Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 705: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 706: Screw Joints
9.4 Screw joints 9.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 707 Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated Continues on next page Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 708 Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Lubricated with Molycote 1000, Gleitmo 603 or equivalent Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 709: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 710: Standard Toolkit
Ratchet head for torque wrench 1/2 Hex socket head cap no. 2.5 socket 1/2" bit L=110 mm Small screwdriver T-handle with ball head Small cutting plier Plastic mallet Needle-nose plier Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 711: Special Tools
Required if Axis Calibration is the valid calibration method for the robot. The tool box also includes a unique calibration pin for CRB 1100 to be fitted to the tool flange during calibration of axis 6. Sonic tension meter Used for measuring the timing belt tension.
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Page 713: Spare Parts
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - CRB 1100 3HAC078007-001 Revision: J...
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Page 715 657 hot gearbox oil, 685–686 CalibWare, 654 hot surfaces, 31 carbon dioxide extinguisher, 28 housing cleaning, 168 replacing, 393 Cold environments, 93 HRA, 28 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 716 362 replacing, 535 mechanical stop motor, axis-5 axis 1, 87 replacing, 524 motor motor, axis-4 axis-6, 535 replacing, 513 axis-5, 524 motor, axis-3 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 717 56 shipping, 699 wall mounting, 60 signals weight, 38 safety, 19 robot, 56 SMB unit working range, 47 replacing, 269 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 718 Index robot, 45 wrist replacing, 435 replacing, 51 Wrist Optimization overview of method, 679 zero position checking, 682 Product manual - CRB 1100 3HAC078007-001 Revision: J © Copyright 2021-2023 ABB. All rights reserved.
Page 720 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2021-2023 ABB. All rights reserved. Specifications subject to change without notice.

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