IRC5-IRB2400 Prod Man Part2 3HAC022031-001 - Reva - en - References

Product manual (part 2 of 2), reference information
Articulated robot
IRB 2400 - L IRB 2400 - 10 IRB 2400 - 16 M2000,M2000A, M2004
Product manual (part 2 of 2), reference information Articulated robot IRB 2400 - L IRB 2400 - 10 IRB 2400 - 16
M2000 M2000A M2004 Document ID: 3HAC 022031-001 Revision: A
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABBs written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2004 ABB All right reserved. ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1 Reference information 9
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.7 Standard toolkit, IRB 2400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2 Part list 3 Foldouts 4 Circuit diagram 21 23 25
3HAC 022031-001 Revision: A
Overview
Overview
About this manual This manual contains reference information for all procedures described in the Product manual, procedures . Usage This manual should be used during installation maintenance work repair work.
Who should read this manual? This manual is intended for: Prerequisites The reader should... be a trained maintenance/repair craftsman have the required knowledge of mechanical and electrical installation/repair/ maintenance work. installation personnel maintenance personnel repair personnel.
Organization of chapters The manual is organized in the following chapters: Chapter

Reference information
Contents
Useful information when performing installation, maintenance or repair work (lists of necessary tools, reference documents, safety standards). Complete list of manipulator parts, shown in the exploded views or foldouts. Detailed illustrations of the manipulator with reference numbers to the part list. Circuit Diagram of the manipulator.
Part list Exploded views / Foldouts Circuit Diagram
References Reference Document Id
Overview
Revisions Revision
-
Description
First edition. Replaces previous manuals: Installation and Commssioning Manual Maintenance Manual Repair Manual, part 1 Repair Manual, part 2. Changes made in the material from the previous manuals: Model M2004 implemented. Section Document references is completed with article numbers for calibration manuals.
Product documentation, M2000/M2000A
Product documentation, M2000/M2000A

General The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below: Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including intervals) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning)
Product manual, reference information Software manuals The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation. A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: Installation information Repair information Maintenance information Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams
In addition, spare part information is supplied for the entire option.
Product documentation, M2004

General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including intervals) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning)
Product manual, reference information RobotWare manuals The following manuals describe the robot software in general and contain relevant reference information: RAPID Overview: An overview of the RAPID programming language. RAPID reference manual part 1: Description of all RAPID instructions. RAPID reference manual part 2: Description of all RAPID functions and data types. Technical reference manual - System parameters: Description of system parameters and configuration workflows. Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams
Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about:
The purpose of the application (what it does and when it is useful) What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
7
Operators manuals
How to use the application Examples of how to use the application
This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These include: Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system) Operators manual - IRC5 with FlexPendant Operators manual - RobotStudioOnline Trouble shooting Manual for the controller and robot
1 Reference information
1.1. Introduction
1.1. Introduction
General This chapter includes general information, complementing the more specific information in the Product manual (part 1 of 2), procedures.
1.2. Applicable Safety Standards
1.2. Applicable Safety Standards

Standards, general The robot is designed in accordance with the requirements of: Standards, safety fence The following standards are applicable to the safety fence surrounding the robot cell: Standards, robot cell The following standards are applicable when the robot is part of a robot cell: IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs. EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body. EN 811 Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs. Pr EN 999 Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body. EN 1088 Safety of machinery - Interlocking device associated with guards principles for design and selection. ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing systems - Basic requirements prEN 999:1995 ISO10218, Jan. 1992, Industrial Robot Safety ANSI/RIA 15.06-1999 ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing systems - Basic requirements DIN 19258 - Interbus-S, International Standard
10
1.3. Unit conversion
1.3. Unit conversion

Converter table Use the table below to convert units used in this manual.
Quantity
Length Weight Pressure Force Moment Volume
Units
1m 1 kg 1 bar 1N 1 Nm 1L 3.28 ft 2.21 lb 100 kPa 0.738 lbf 0.738 lbf-tn 0.264 US gal 14.5 psi 39.37 in
11
1.4. Screw joints
1.4. Screw joints

General This section details how to tighten the various types of screw joints on the robot and the controller. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue. Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed! Using other types of screws will void any warranty and may potentially cause serious damage or injury! Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions. In such cases, proceed as follows: 1. Apply lubricant to the screw thread. 2. Apply lubricant between the plain washer and screw head. 3. Tighten to the torque specified in section Tightening torque below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
Lubricant
Molycote 1000 (molybdenum disulphide grease)
Art. no.
1171 2016-618
Tightening torque Before tightening any screw, note the following: Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value. Use the correct tightening torque for each type of screw joint.
12
1.4. Screw joints
Only use correctly calibrated torque keys. Always tighten the joint by hand, and never use pneumatical tools. Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion. Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.
Dimension
M2.5 M3 M4 M5 M6
Tightening torque (Nm) Class 4.8, oil-lubricated

0.25 0.5 1.2 2.5 5.0
The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws.
Dimension
Tightening torque (Nm) Class 8.8, oillubricated

6 10 24 47 82 200

34 67 115 290

40 80 140 340
M5 M6 M8 M10 M12 M16
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension
M8 M10 M12 M16
Tightening torque (Nm) Tightening torque (Nm) Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
28 55 96 235 34 66 115 280
13
1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.
Dimension
1/8 1/4 3/8 1/2 3/4
Tightening torque Nm - Nominal

12 15 20 40 70
Tightening torque Nm - Min.

8 10 15 30 55
Tightening torque Nm - Max.

15 20 25 50 90
14
1.5. Weight specifications
1.5. Weight specifications

Definition In all repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model. Example Below is an example of how a weight specification is presented: CAUTION! Caution! The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
15
1.6. Document references

General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentation. Product specification, robot The product specification includes generic technical data. The specification listed below is the English version.
Document name
Product specification
Document ID
3HAC 9112-1
Product manuals, controller The product manuals include information about installation and service activities. The table below specifies the article numbers of the product manuals for all controller models. The part number -001 is the English version.
Document name
Product manual, S4Cplus M2000 Product manual, S4Cplus M2000A Product manual, IRC5 M2004
Document ID
3HAC 021333-001 3HAC 021128-001 3HAC 021313-001
Operators manual The operators manual contains instructions for daily operation of robot systems. The table below specifies the article numbers of the operators manuals for different robot systems.
Document name
Users guide (S4Cplus) Operators manual (IRC5)
Document ID
3HAC 7793-1 3HAC 16590-1
Note
Contains instructions for daily operation of S4Cplus based robot systems.
Calibration manuals Document name

Calibration Pendulum Instruction Instructions for Levelmeter calibration (alternative method) CalibWare 2.0 Users Guide
Document ID
3HAC 16578-1 3HAC 022907-001 3HAC 16090-1
Note
Enclosed with the Calibration Pendulum Toolkit. Enclosed with the Levelmeter 2000. Calibration tool for Absolute Accuracy calibration.
16
Additional documentaion Document name

External axes
Document ID
3HAC 9299-1
Note
17
1.7. Standard toolkit, IRB 2400
1.7. Standard toolkit, IRB 2400

General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction. Contents Qty Tool
1 1 1 1 1 1 1 1 1 1 Ring-open-end spanner 8-19mm Socket head cap 2,5-17mm Torx socket no:20-60 Torque wrench 10-100Nm Small screwdriver Ratchet head for torque wrench 1/2 Socket head cap no:5, socket 1/2"" bit L 20mm Socket head cap no:6, socket 1/2"" bit L 20mm Socket head cap no:8, socket 1/2"" bit L 20mm Small cutting plier
18
1.8. Lifting equipment and lifting instructions

General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment. This implies that the instructions delivered with the lifting equipment should be stored for later reference.
19
20
2: Part list
2.0.1 Introduction
Definitions This chapter is an appendix to the manual and contains part lists for the manipulator. The item numbers refers to chapter Foldouts on page 35. The part list for the manipulator sometimes differ between robot versions.
21
2.0.2 Foot
Foot Itm
1 2 3 4 5
Item number refers to item number on the foldouts.Customer Qty

1 1 12 12 2 2 1 6 7 8 9 3 12 4 8
cable
Name
Foot Gear box axes 1-3 Hex socket head cap screw Plain washer Motor axes 1 and 3 Motor axes 1 and 3 Motor axes 1 O-ring Spring washer Hex socket head cap screw Hex socket head cap screw
Art. No.
3HAC 5945-1 3HAC 4795-1 3HAB 3402-69 9ADA 312-9 3HAC 4789-1
Remarks
M12x50 8.8 Gleitmo 610 Gleitmo 610 13x24x2.5
3HAC 021346-001 5/10/16/kg, Yaskawa 3HAC 021961-001 Wall ,Yaskawa 2152 2012-434 2154 2033-9 3HAB 3409-45 3HAB 3409-37 109.5x3 8.4x18x2 M8x65 12.9 Gleitmo 610 M8x25 12.9 Gleitmo 610
Axis 4Lower
Itm Qty 1
arm
Name Art. No. Remarks Option 043 See below
Customer cable extension, axis 4 3HAC 8869-1
2400L/10, /16Upper Itm Qty

1 1 11 12 13 14 15 16 17 8 12 1 1 1 4 8
Arm IRB 2400/10/16

Art. no.
3HAC 4796-1 3HAC 4797-1 2154 2033-10 3HAB 3409-50 3HAC 2205-1 3HAC 2180-1 3HAB 5512-1 9ADA 629-56 3HAB 3409-57 M6x16 M10x60 12.9
Name
Lower arm Lower arm Spring washer Hex socket head cap screw Spring tension plate Damper, standard axis 2 Damper axis 3 Torx pan head roll. screw Hex socket head cap screw
Remark
2400/10, /16 2400L 10.5x23x2.5 M10x40 12.9 66x116x3
22
Itm
18 19 20 21 26 32 33 34 35 36 41 42 43 46 48 49 50 51 54 55 56 57 60 62 63 100 102 103 104 104 104 105 106 107 108 109 110 111 112 114 115 116 3HAC 022031-001 Revision: A
Qty
1 2 1 2 2 1 1 1 1 1 1
Name
Parallel arm Sealing ring Groove ball bearing Sealing ring Hex socket head cap screw Sealing Locking washer Hex socket counters, head Sealing Motor axis 2 Motor axis 2 Lubricating oil Bearing grease Locking liquid
Art. no.
3HAB 9394-1 3HAB 3732-13 3HAB 3643-12 3HAB 5515-1 9ADA 183-34 3HAC 10089-2 3HAB 5523-1 2121 2852-449 3HAC 10088-4 3HAC 4790-1
Remark
V-110-L 99x10.5 61822-2RS1 Acetal M8x12 SS 1914-04 M8x16 8.8 Acetal (POM)
3HAC 021350-001 5/10/16/kg, Yaskawa 1171 2016-604 3HAB 3537-1 3HAB 7116-1 3HAB 6687-1 2151 2082-150 3HAC 0447-1 3HAB 5522-1 2126 2851-107 3HAB 5527-1 3HAB 7700-71 3HAA 2166-15 3HAB 8385-1 3HAA 1001-134 9ADA 629-43 3HAC 4791-1 3HAC 2828-1 3HAC 4554-1 3HAC 9368-1 3HAC 9362-1 3HAC 7242-1 3HAC 3200-1 3HAC 4113-1 3HAB 5923-1 3HAB 3299-1 3HAB 5924-1 3HAB 3662-1 3HAB 5928-1 3HAC 4337-1 3HAC 2589-1 3HAB 3700-1 9ADA 629-45 M5x16 23 IRB 2400/10/16 Standard Foundry Wire feeder M35x1.5 SS 1672-08 M12x60 12.9 VK 62x8 6.1x20x2 14 700 ml 1g 1 ml Loctite 243
1 6 1 1 1 2 2 2 2 1 2 9 1 1 1 1 1 1 1 1 1 2 1 1 1 3 1 1 2
Stop axis 1 Washer Friction washer Sync. mark. axis 2 Upper arm axes 4-6 Lock nut Shaft end Hex socket head cap screw VK-cover Sync. market axis 3 Washer Torx pan head roll screw Cable unit axes 1-3 Bottom plate Gasket Cover Cover Cover Gasket Sealing Bracket Holder for cable guide Cable guide Spring Cable guide upper arm Cover Instruction plate Serial meas. board Torx pan head roll. screw
Itm
117 118 119 121 122 123 125 129 132 133 134 135 136 137 138 139 140 141 147 149 150 151 152 156 157 157 158 159 160 161 168 169 170 171
Qty
1 14 12 1 4 1 1 1 2 1 15 3 8 63 6 1 2 3 1
Name
Battery unit Hexagon nut with flange Cable straps, outdoor Push button unit Distance bolt Push button cover Cable straps, outdoors Signal cable SMB Dust cap Dust cap Torx pan head screw Hex socket head pan screw Torx pan head roll. screw Torx pan head roll. screw Cable straps, outdoors Coupling Locking liquid Protective hood Gasket Gasket Flange sealing Adhesive tape
Art. no.
4944 026-4 9ADA 290-1 2166 2055-3 3HAC 0017-1 2125 2052-198 3HAC 2744-1 2166 2055-7 3HAC 7819-1 3HAC 7561-3 3HAC 7561-4 9ADA 618-56 9ADA 183-34 9ADA 629-34 9ADA 629-44 2166 2055-1 3HAB 3333-20 1269 0014-412 2522 2101-8 3HAC 4419-1 3HAB 7160-1 1234 0011-116 1169 9198-301 3HAB 5921-1 3HAC 3785-1 3HAB 7328-1 3HAC 6823-1 3HAB 2809-1 3HAC 7816-1 3HAC 5479-3 3HAC 5479-4 3HAC 3189-1 3HAB 9040-1 3HAC 0048-1 1866 1903-1
Remark
M5 fzb L=208 mm M5x15 8.9x780
M6x16 8.8 M8x12 8.8 M4x12 Ext. conn. M5x12 L=101 mm Loctite 542 D=11.4 - 13
Loctite 574 19x0.18
1 1 1 1 1 2 1 1 1 2 1
Bracket Parallel pin Adaptor, customer cabling Cover protection Adaptor, power cabling Protection cover Sealing Sealing Protective hood Gasket Cover Profile
Foundry
Suspended Standard 120 mm
Axes 4-6Upper Itm

45 46 47 48 49
Arm IRB 2400L

Art. no.
3HAC 10089-2 3HAB 5511-1 3HAC 0001-1 3HAC 10088-4 2121 2852-449 M8x16 8.8
Qty
2 1 1 1 1
Name
Sealing Damper axis 3 Bracket Sealing Hex socket counters, head
Remark
24
Itm
50 51 52 53 54 55 56 57 57 58 59 60
Qty
1 3 1 9 9 1 1 10 2 1 1 1
Name
Locking washer Locking liquid Gasket Cable unit axes 4-6 Torx pan head screw Cable straps, outdoors Adhesive tape Cover Cover with lamp unit Torx pan head roll. screw Hex socket head cap screw Motor unit axis 6 Motor unit axis 6 Motor unit axis 6 Upper arm without wrist and motors Disc spring Wrist Wrist O-ring Hex socket head cap screw Plain washer Motor unit axis 5 Motor unit axis 5 Motor unit axis 5 Motor unit axis 5 Motor unit axis 4 Motor unit axis 4 Motor unit axis 4 O-ring Plain washer Hex socket head cap screw Damper axis 4 Hex socket head cap screw Lubricating oil
Art. no.
3HAB 5523-1 3HAB 7116-1 3HAC 4429-1 3HAC 9328-1 9ADA 618-46 2166 2055-1 1169 9198-301 3HAB 6491-1 3HAC 2774-1 9ADA 629-44 9ADA 183-22 3HAC 10602-2
Remark
SS 1914-04 6 ml, Loctite 243
M5x20 8.8 2.5x101 500 mm, 19x0.18
M5x12 M6x10
3HAC 021731-001 10/16 kg, Yaskawa 3HAC 021741-001 5 kg, Yaskawa 3HAC 1581-1 3HAB 3731-14 3HAB 9439-1 3HAB 9398-1 3HAB 3772-12 3HAB 3402-38 9ADA 312-7 3HAC 10600-1 3HAC 10601-1 67.5x50.5x0.7 Standard Foundry Nitrile rubber 126x4 M8x30 8.8 Gleitmo 610 8.4x16x1.6 10 kg 16 kg
1 13 18 18 19 20 21 25
1 4 1 1 1 6 15 1 1 1
3HAC 021741-001 5 kg, Yaskawa 3HAC 021722-001 10/16 kg, Yaskawa 3HAC 10602-1 3HAC 021740-001 5 kg, Yaskawa 3HAC 021353-001 10/16 kg, Yaskawa 3HAB 3772-1 9ADA 312-6 3HAB 3409-26 3HAB 5544-1 3HAB 3402-36 3HAC 0860-1 2522 122-1 2152 2031-6 3HAB 3537-1 1234 0011-116 50 g 30 ml, Loctite 574 M8x20 8.8 Gleitmo 610 2300 ml R1/4 Nitrile rubber 34.2x3 6.4x12x1.6 M6x25 12.9 Gleitmo 610
26
2 2 2
27 28 29 30 32 33 34 35 39 40
3 12 12 1 4
2 2
Magnetic plug Sealing ring Bearing grease Flange sealing
25
Itm
41 42 43 44
Qty
2 2 1 2
Name
Sealing ring without dust lip Taper roller bearing Parallel bar Spherical roller bearing
Art. no.
3HAC 7877-2 3HAA 2103-15 3HAC 1564-1 3HAA 2167-12
Remark
32007 X 22206 CC
PartsDrive Itm
1 2 3 4 5 6 7 8 9 10 11 12 13 14
unit IRB 2400/10/16

Name
Tubular shaft Back-up ring Sealing ring Ball bearing Cover plug Housing, axis 4 Spacer Spacer Spacer Gear, axis 4, step 2 Damper, axis 4 Hex socket head cap screw Plain washer Hex socket head cap screw
Qty
1 1 1 2 2 1 2 4 1 1 1 6 10 4
Art. no.
3HAC 0235-1 3HAB 6354-1 3HAB 3732-13 2213 253-12 2216 264-14 3HAC 0236-1 2159 167-61 2159 167-62 2159 167-63 3HAB 3210-1 3HAB 6356-1 3HAB 3402-24 9ADA 312-6 3HAB 3402-30
Remark
99x10.5 V-110-L 105x130x13 61821-2RSI IRB 2000 D=115/105, T=0.05 D=115/105, T=0.1 D=115/105, T=0.5
M6x16 8.8 Gleitmo 610 6.4x12x1.6 A2F M6x45 8.8, Gleitmo 610
Drive unit axis 5-6Drive Itm

45
unit IRB 2400L

Art. no.
2166 2055-1
Qty
10
Name
Cable straps, outdoors
Remark
2.5x101 Polyamide 6.6 black D=6 5562-00-04 D=11 5562-00-07
46 47 48 49 50 51
1 1 1 2 1 1
Clamp Clamp Bracket, axes 5-6 Torx pan head roll screw Parallel bar Damper, axis 3
2166 2018-8 2166 2018-2 3HAB 3230-1 9ADA 629-47 3HAC 1563-1 3HAB 5511-1
M5x25 8 A2F
Itm
52 53
Qty
2 2
Name
Hex socket head cap screw Spherical roller bearing
Art. no.
9ADA 183-22 3HAA 2167-12
Remark
M6x10 8.8 A2F D=30/62 W=20 22206 CC Standard
54 55 56 57 58 59 59 60 61 15 16 17 18 23 24 25 28 30 31 32 34 35 36 37 38 39 40 43 44
2 1 1 1 1 1 1 3 1 1 1 4 1 1 2 2 1
Sealing Sealing Locking washer Hex socket head cap screw Cable bracket upper arm Cable unit axes 4-6 Cable unit axes 4-6 Gasket Cable straps, outdoors Drive unit axis 5-6 Motor unit, axis 4 Hex socket head cap screw O-ring Gear unit, axis 4 Plain washer Hex socket head cap screw Cover Lubricating oil Locking liquid Locking liquid Flange sealing Bearing grease
3HAC 10088-4 3HAC 10089-2 3HAA 2356-11 3HAB 3402-36 3HAB 5927-1 3HAC 9330-1 3HAC 13052-1 3HAB 4429-1 2166 2055-3 3HAC 11864-1 9ADA 183-14 2152 2011-414 3HAB 3380-1 9ADA 312-7 9ADA 183-38 3HAB 6355-1 1171 2016-604 3HAB 7116-1 1269 0014-413 1234 0011-116 3HAB 3537-1 3HAC 10814-1 3HAB 3402-25 3HAB 4350-1 3HAC 2743-1 9ADA 629-44 3HAB 4405-1 3HAB 7877-2 3HAA 2103-15 D=42/55 W=8 Nitrile rubber D=35/62 W=18 32007 X Option M5x12 8 30 ml Loctite 243 Loctite 638 Loctite 574 Shell Retinax MS Standard and Foundry M6x20 8.8, Gleitmo 610 8.4x16x1.6, A2F M8x30 8.8, A2F M5x16 8.8, A2F 44.2x3, Nitrile rubber Wire feeder 9x35x3 M8x20 8.8 Gleitmo 610
1 6 1 1 39 1 2 2
Wrist, 5 kg Hex socket head cap screw Cover Cover with lamp unit Torx pan head roll screw Cover Sealing ring (without dust lip) Taper roller bearing
27
Axes 5-6Limit Itm

1 2 3 4 5 6 7
Switch
Name
Drive shaft unit, axes 5-6 Motor unit axes 5-6 Motor plate Hexagon nut Hex socket head cap screw Plain washer Gear belt
Qty
1 2 1 8 10 10 2
Art. no.
3HAC 11804-1 3HAC 11865-1 3HAA 2504-1 9ADA 267-5 3HAB 3402-14 9ADA 312-5 3HAA 2393-1
Remark
M5 8. A2F M5x16 8.8 Gleitmo 610 5.3x10x1. A2F
Axis 1 Itm
1 2 3 4 5 6 7 7 8 9 10 11 12 13 14
Qty
3 2 6 7 24 1 2 0 1 6 9 4 6 1 1 2
Name
Switches Holder ring Hexagon screw, button head Cam, blank Torx pan head screw Attachment plate Torx pan head screw Position switch 1 Position switch 1-3 Hex socket head cap screw Shims-sheet Torx pan head roll. screw Clamp Cable straps, outdoors Assembly instruction Torx pan head screw
Art. no.
3HAC 0305-1 3HAC 0596-31 3HAB 8086-1 9ADA 618-55 3HAC 0982-1 9ADA 618-56 3HAC 6447-1 3HAC 6448-1 9ADA 183-5 3HAB 7478-1 9ADA 629-42 2166 2018-9 2166 2055-3 3HAB 8372-1 9ADA 618-59
Remark
M8x12 M6x12 M6x16
M4x16 M5x8 D=8 4.8x208 Incl. in the delivery. M6x30.
28
3 Foldouts
3 Foldouts
29
3 Foldouts
30
4 Circuit diagram
4 Circuit diagram
31
Manipulator Circuit Diagram
3HAC 6670-3 Rev.01
LIST OF CONTENTS
No. of Sheets 13
Product Manual IRB 2400
Sheet no.
101
3HAC 6670-3 Rev.01
CONNECTION POINT LOCATIONS

No. of Sheets 13
Sheet no.
102
3HAC 6670-3 Rev.01
BREAK UNIT
No. of Sheets 13
Sheet no.
103
3HAC 6670-3 Rev.01
MOTOR AXIS 1 - 3
No. of Sheets 13
Sheet no.
104
3HAC 6670-3 Rev.01
SERIAL MEASUREMENT BOARD

No. of Sheets 13
Sheet no.
105
3HAC 6670-3 Rev.01
MOTOR AXIS 4 - 6, 1.5 - 10 / 16

No. of Sheets 13
Sheet no.
106
3HAC 6670-3 Rev.01
FEED- BACK AXIS 4 - 6, 1.5 10 / 16

No. of Sheets 13
Sheet no.
107
3HAC 6670-3 Rev.01
MOTOR AXIS 4 - 6, 1.8 - 5

No. of Sheets 13
Sheet no.
108
3HAC 6670-3 Rev.01
FEED - BACK AXIS 4 - 6, 1.8 - 5

No. of Sheets 13
Sheet no.
109
3HAC 6670-3 Rev.01
CUSTOMER CONNECTIONS
No. of Sheets 13
Sheet no.
110
3HAC 6670-3 Rev.01
INTEGRATED WIREFEED CABLING (OPTION)

No. of Sheets 13
Sheet no.
111
3HAC 6670-3 Rev.01
POS. INDICATOR AXIS 1 (OPTION)

No. of Sheets 13
Sheet no.
112
3HAC 6670-3 Rev.01
EXTERNAL CONNECTIONS (OPTIONS)

No. of Sheets 13
Sheet no.
113
ABB Automation Technologies AB Robotics S-721 68 VSTERS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592
3HAC 022031-001, Revision A, en

IRC5-IRB2400 Prod Man Part2 3HAC022031-001 - Reva - en - References

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IRC5-IRB2400 Prod Man Part2 3HAC022031-001 - Reva - en - References

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Product manual (part 2 of 2), reference information

3HAC 022031-001 Revision: A

Organization of chapters The manual is organized in the following chapters: Chapter

Part list Exploded views / Foldouts Circuit Diagram

References Reference Document Id

3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

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

3HAC 022031-001 Revision: A

Product documentation, M2004

Product documentation, M2004

Product documentation, M2004

How to use the application Examples of how to use the application

3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A

1.2. Applicable Safety Standards

3HAC 022031-001 Revision: A

1.3. Unit conversion

3HAC 022031-001 Revision: A

1.4. Screw joints

Tightening torque (Nm) Class 4.8, oil-lubricated

Tightening torque (Nm) Class 8.8, oillubricated

Tightening torque (Nm) Class 10.9, oillubricated

Tightening torque (Nm) Class 12.9, oillubricated

M5 M6 M8 M10 M12 M16

3HAC 022031-001 Revision: A

Tightening torque Nm - Nominal

Tightening torque Nm - Min.

Tightening torque Nm - Max.

3HAC 022031-001 Revision: A

1.5. Weight specifications

3HAC 022031-001 Revision: A

1.6. Document references

Calibration manuals Document name

3HAC 022031-001 Revision: A

Additional documentaion Document name

3HAC 022031-001 Revision: A

1.7. Standard toolkit, IRB 2400

3HAC 022031-001 Revision: A

1.8. Lifting equipment and lifting instructions

3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A

Item number refers to item number on the foldouts.Customer Qty

M12x50 8.8 Gleitmo 610 Gleitmo 610 13x24x2.5

Customer cable extension, axis 4 3HAC 8869-1

2400L/10, /16Upper Itm Qty

Arm IRB 2400/10/16

3HAC 022031-001 Revision: A

Loctite 574 19x0.18

Suspended Standard 120 mm

Axes 4-6Upper Itm

Arm IRB 2400L

3HAC 022031-001 Revision: A

M5x20 8.8 2.5x101 500 mm, 19x0.18

Magnetic plug Sealing ring Bearing grease Flange sealing

3HAC 022031-001 Revision: A

unit IRB 2400/10/16

Drive unit axis 5-6Drive Itm

unit IRB 2400L

3HAC 022031-001 Revision: A