Professional Documents
Culture Documents
IRC5-IRB2400 Prod Man Part1 3HAC022031-001 - Reva - en - Procedures PDF
IRC5-IRB2400 Prod Man Part1 3HAC022031-001 - Reva - en - Procedures PDF
Articulated robot
IRB 2400 - L
IRB 2400 - 10
IRB 2400 - 16
M2000,M2000A, M2004
Product manual, (part 1 of 2), procedures
Articulated robot
IRB 2400 - L
IRB 2400 - 10
IRB 2400 - 16
M2000
M2000A
M2004
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Maintenance 61
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Maintenace schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Changing activites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.1 Change of oil in wrist unit IRB 2400/10/16 /L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.2 Change the backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Repair 71
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3.1 Removal of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3.2 Refitting of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.4.1 Removal of wrist IRB 2400/10/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.4.2 Refitting of wrist IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4.3 Removal of wrist IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.4.4 Refitting of wrist IRB 2400L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.4.5 Removal of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.4.6 Reassemble of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.5.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.5.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.5.3 Removal of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5.4 Reassemble of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.6.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.6.2 Reassemble of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.6.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.6.4 Reassemble of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.6.5 Removal of the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.6.6 Reassemble of the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.7.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.7.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.7.3 Removal of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.7.4 Refitting of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.7.5 Removal of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.7.6 Refitting of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7.7 Removal of motor, axis 4-6;IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.7.8 Refitting of motor, axis 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.7.9 Removal of motor, axis 4-6, IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.7.10 Refitting of motor, axis 4-6 IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.8.1 Removal of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.8.2 Refitting of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.8.3 Remove the complete drive mechanism. IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Overview
Usage
This manual should be used during
• installation, from lifting the manipulator to its work site and securing it to the
foundation to making it ready for operation
• maintenance work
• repair work.
Prerequisites
The reader should...
• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/
maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety, service Safety information
Installation and commissioning Information about installation of the manipulator.
Maintenance Information about maintenance work, including
maintenance schedules.
Repair Information about repair work.
Calibration information Procedures that do not require specific calibration
equipment. General information about calibration.
Decommissioning Environmental information about the manipulator.
References
Reference Document Id
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.
A Chapter“ Calibration” replaced with chapter “Calibration information”.
Safety chapter rewritten.
References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an procedure.
Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed. Read more in chapter Safety on page
13.
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
Operator’s manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudioOnline
• Trouble shooting Manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 34.
1.2.1. Introduction
Definitions
This section details general safety information for service personnel i.e. personnel performing
installation, repair and maintenance work.
Sections
The general safety information is divided into the following sections:
1. General information contains lists of:
• Safety, service
• Limitation of liability
• Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split
into different categories:
• Safety risks during service work on robot
• Safety risks related to gripper/end effector
• Safety risks related to tools/workpieces
• Safety risks related to pneumatic/hydraulic systems
• Safety risks during operational disturbances
• Safety risks during installation and service
• Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
• Safety fence dimensions
• Fire extinguishing
• Emergency release of the manipulator´s arm
• Brake testing
• Risk of disabling function "Reduced speed 250 mm/s"
• Safe use of the Teach Pendant Unit enabling device
• Work inside the manipulator´s working range
• Signal lamp (optional)
General
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
have been complied with.
General
The list below specifies documents which contain useful information:
Documents
Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.
Complete robot
Caution!
Warning!
Cabling
Caution!
Caution!
Balancing device
Warning!
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
• Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.
General
• The industrial robot is a flexible tool which can be used in many different industrial
applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.
Qualified personnel
• Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator
or controller)!
Description
In an emergency situation, any of the robot’s axes may be released manually by pushing the
brake release buttons on the robot or on an optional external brake release unit.
How to release the brakes is detailed in section:
• Manually releasing the brakes on page 47.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
When to test
During operation the holding brakes of each axis motor wear normally. A test may be
performed to determine whether the brake can still perform its function.
How to test
The function of each axis’ motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator
arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the
controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
NOTE!
Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant
Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.
NOTE!
The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling
device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
• The enabling device must never be rendered inoperative in any way.
• During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
• The programmer must always bring the Teach Pendant Unit with him/her, when
entering the robot's working space. This is to prevent anyone else taking control over
the robot without the programmer knowing.
WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
• The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position < 250 mm/s. This should be the normal position when entering the working
space. The position 100% ”full speed” may only be used by trained personnel who are
aware of the risks that this entails.
• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
• Test the motor brake on each axis, according to section Brake testing on page 30.
General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel does not
eliminate the danger.
• An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Electrical shock
Electrostatic discharge
(ESD)
Note
Tip
Description
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes irrational
movements. However, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the manipulator
working range.
Elimination
Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not connected to ground potential may transfer
high static charges. This discharge may destroy sensitive electronics.
Elimination
xx0400001055
Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!
Hot oil!
When opening the oil plug, Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
General
This chapter contains information for installing the robot to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.
2.2 Unpacking
General
These instructions are to be used when unpacking and installing the robot for the first time.
They also contain information useful later during re-installation of the manipulator.
Weight
The net weight of the manipulator is approximately: 380 kg.
Loads on foundation
The table below shows the different forces and torques working on the manipulator during
various kinds of operation.
Note! These forces and torques are extreme values that are rarely encountered during
operation. The values also never simultanesously reach their maximum!
IRB 2400 - L
Requirements on foundation
The table below shows the requirements of the foundation where the manipulator is to be
fitted:
Requirement Value
Min. levelity 0.5 mm
Max. tilt 5°
Min. resonance frequency 30 Hz
Storage conditions
The table below shows the allowed storage conditions for the manipulator:
Parameter Value
Max. ambient temperature, storage +55° C
Max. ambient temperature, storage (less than 24 hrs) +70° C
Min. ambient temperature, storage -25° C
Max. ambient humidity, storage Max. 95% at constant temperature
Operating conditions
The table below shows the allowed operating conditions for the manipulator and controller:
Parameter Value
Max. ambient temperature +45° C
Min. ambient temperature +5° C
Max. ambient humidity Max. 95% at constant temperature
Protection classes
The table below shows the protection class of the main parts of the robot system:
IRB 2400L
The working area is the same for both floor and inverted (suspended). Positions at wrist
center.
xx0200000159
Pos.
X Z Angle axis 2
Angle axis 3
0 970 1620 0
0
1 404 2298 0
-60
2 602 745 0
65
3 1577 -246 110
-60
4 400 -403 110
24,5
5 -1611 623 -100
-60
6 -115 1088 -100
65
2400/10, 16
The working area is the same for both floor and inverted (suspended). Positions at wrist
center.
xx0200000160
Pos.
X Z Angle axis 2
Angle axis 3
0 855 1455 0
0
1 360 2041 0
-60
2 541 693 0
65
3 1351 -118 110
-60
4 400 -302 110
18,3
5 -1350 624 -100
-60
6 -53 1036 -100
65
General
This section details how to lift the manipulator using lifting slings.
Equipment Note
Sling line Type: KDBK 7-8. Length: 2 m. Load at 90°: 380 kg.
Illustration
The following figure shows how to lift the manipulator with lifting slings.
xx0200000164
General
he section below details how to release the holding brakes of each axis’ motor.
This may be done in one of three ways:
• using the pushbutton when the manipulator is connected to the controller.
• using the pushbutton on the manipulator with an external power supply.
• using an external voltage supply.
DANGER!
When pushing the button all axes are released, the axes become activated very quickly and
the robot may collapse in an unexpected way and cause damage or personal injury.
xx0200000168
• A: Pushbutton
xx0200000167
• A: R1.MP
• B: Push button
• C: B8 = +24 V
• D: C10 = 0V
2. Push the "brake release button"
to release the holding brakes,
see the previous illustration.
CAUTION!
Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can
be caused to a resistor diode and to the system board.
General
This section details how to orient and secure the manipulator to the foundation in order to
safely run the robot. The requirements for the foundations are shown in the tables and figures
below.
Bolting requirements
When bolting a mounting plate or frame to a concrete floor, follow the general instructions
for expansion-shell bolts. The screw joint must be able to withstand the stress loads difined
in section “Loads on foundation”.
NOTE!
When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must
be used to secure the bolted joint.
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
manipulator to the base plate/foundation.
Hole configuration
The illustration below shows the hole configuration used when securing the manipulator:
xx0200000181
xx0200000182
Guide bushings
Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be
remounted without re-adjusting the program.
General
The IRB 2400 robot can be mounted in a suspended position, following information is to be
consider when turning the manipulator.
xx0200000212
A Lifting beam
B Fork lift
- Inverted mounting tool 3HAC 8961-1
2. Seal the eight holes in the bottom plate with plastic plugs, see following illustration.
xx0200000215
2.3.5. Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of center of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operational stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in User’s
Guide (RobotWare 4.0), or Operator’s manual (RobotWare 5.0).
2.4.1. Introduction
General
When installing the robot, make sure that it can move freely within its entire working space.
If there is a risk that it may collide with other objects, its working space should be limited.
The working range of the robot may be limited to eliminate the risk of collisions. The
following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
• Axis 2, hardware (mechanical stop) and software (signal from adjustable position
switch)
• Axis 3, hardware (mechanical stop) and software (signal from adjustable position
switch)
This section describes the use of the mechanical stops and/or the position switches.
Notice that adjustments must be made also in the software, references to software manuals
are given in following installation procedures.
General
The axis 1 working range may be restricted mechanically.
Stops
The working range may be restricted by fitting a mechanical stop.
If the robot should run into one of these stops during operation, the mechanical stop pin and
the extra moveable mechanical stop arm for axis 1 must be replaced!
xx0200000205
xx0200000206
Drill pattern
xx0200000207
General
The range of rotation for axis 2 can be limited mechanically by fitting extra stops on the lower
arm.
xx0200000208
General
The working range of axis 3 can be limited by fitting an electrical switch on the gear box axis
3, which senses the position via a cam.
xx0200000211
3 Maintenance
3.1. Introduction
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Make sure
to read through the chapter Safety on page 13.
Description
The intervals may be specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the robot:
• Calendar time: specified in months regardless of whether the robot system is run or not
• Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
General
The robot must be maintained regularly to ensure proper function. The maintenance activities
and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.
Maintenance Detailed in
Interval Note
activity section:
Oil change in wrist After first 4,000 h, Change of oil in wrist
unit then every 60 mth.1 unit IRB 2400/10/16 /
12,000 h2 L on page 64
Change of back-up 12-36 mths 3 Measuring the Change the backup
battery for SMB unit capacity of the battery on page 67
battery backup unit to
the SMB
Inspection of all 36 mths Replace if required.
signal cabling in
lower and upper arm
Replacement of 60 mths Replace if bent. Replacement
mechanical stop axis detailed in section .
1
Oil change in 40,000 h Lubricated for life.
gearboxes, axes 1,2, Maintenance free
3 and 4 units.
1. Change the oil for the first time after 4,000 h, then after every 60 month.
2. Valid interval if the robot is working in an environment temperature over 40ºC.
3. The battery is used as a back-up when the robot system is switched off. Therefore, the
life of a lithium battery depends on how frequently the power to the system is switched
off and also if the environment temperature is higher than recommended operating
temperature. The life varies from 12 - 36 mths, depending on current conditions. An
alert is given on the TPU when the battery is nearly discharged and it must then be
replaced within a month.
xx0300000069
A Oil plugg
B Oil plugg (air inlet when draining from oil plug A)
Required equipment
Spare
Equipment Art. no. Note
part no.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures may be These procedures include
required. See references to these references to the tools
procedures in the step-by-step required.
instructions below.
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
xx0300000120
xx0300000121
xx0300000067
Required equipment
Measuring
The procedure below details how to measur the SMB power backup unit
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Always make sure the cable and hose package is secured with the straps delivered with the
kit. These are specially designed not do damage the cables or hoses.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Alternative Battery
Alternative Battery As an alternative to the Ni-Cd battery a lithium battery of primary type
can be installed. The lithium battery needs no charging and has for that reason a blocking
diode which prevents charging from the serial measurement board.
The benefit with a lithium 10.8 V battery is the lifetime, which can be up to 5 years in service,
compare with the Ni-Cd battery’s max life time of 3 years in service.
Two lithium batteries exists:
A 3-cell battery art. No. 3HAB 9999-1
A 6-cell battery art. No. 3HAB 9999-2
The life time of the lithium battery depends on how frequently the user switches off the
power.
The estimated max life time in years for the different lithium batteries and the recommended
exchange interval is shown below
Exchange 3- Exchange 6-
User type:
cell: cell:
Vacation (4 weeks) power off every 5 years every 5 years*
Weekend power off + user type 1 every 2 years every 4 years
Weekend power off + user type 1 and 2 every year every 2 years
* Because of material ageing the maximum life time in
service is 5 years.
Min Max
Ni-Cd 7.0 V 8.7 V
Lithium 7.0 V -
4 Repair
4.1. Introduction
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equipment
Procedure
General
This section details how to mount and grease different types of bearings on the manipulator.
Equipment
Greasing of bearings
The bearings must be greased after assembly, according to instructions below:
• The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available volume.
• Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the split
condition.
General
This sections details how to mount different types of seals to the manipulator.
Equipment
Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.
O-rings
The procedure below details how to fit o-rings.
xx0200000396
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
xx0200000399
xx0200000398
xx0200000400
7. Unscrew the four screws securing the This releases the cable harness from the
cable gland. frame.
8. Remove the adapter plate from the
harness by removing its two attachment
screws.
xx0200000404
xx0200000401
xx0200000396
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
xx0200000399
xx0200000403
xx0200000400
7. Unscrew the four screws securing the This releases the cable harness from the
cable gland. frame.
8. Remove the adapter plate from the
harness by removing its two attachment
screws (A).
xx0200000404
xx0200000405
xx0200000406
xx0200000396
Spare part
Equipment, etc. Art. no. Note
no.
Cable unit, axes 1-3 3HAC 4791-1
Cable unit, axes 4-6 3HAC 8865-1
Cable unit, axes 4-6 Opt 3HAC 8520-1 Option 043
043
Motor gasket for motor 1-3 3HAC 4419-1
Motor gasket for motor 4-6 3HAB 4429-1
Sealing 3HAB 5922-1
Loctite 574 1234 0011-116 Flange sealing
Cable straps 2166 2055-3 L=208mm
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
xx0200000401
5. Mount the back cover of the motors 1-3 Use the 5 Torx screw fitted in the holes
(C) in figure above.
6. Mount the upper bracket securing the
cables to the arm house, using the two
attachment screws.
xx0200000404
xx0200000402
xx0200000400
xx0200000398
xx0200000403
xx0200000399
xx0200000406
xx0300000063
xx0300000062
xx0200000404
xx0200000402
xx0200000400
xx0200000398
xx0200000403
xx0200000399
Location of wrist
The wrist is defined as the manipulators axis 5 and 6, This is shown in pos (A) in the figure
below.
xx0200000409
A Wrist
B Upper arm
C Lower arm
D Frame
E Fot
Required equipment
Location
The procedure below details how to remove the wrist from the robot upper arm.
xx0300000104
A Screws
B Oil-plug
C Wrist
The wrist, which includes axes 5 and 6, is a complete unit comprising drive units and
gearboxes. It is a replacement unit of complex design and should not normally be serviced
on-site. Instead it should be sent to ABB for service etc.
ABB recommends its customers to carry out only the following servicing and repair work on
the wrist.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
Location of wrist
The wrist is defined as the manipulators axis 5 and 6. This is shown in pos (A) in the figure
below.
xx0200000409
A Wrist
B Upper arm
C Lower arm
D Frame
E Foot
Required equipment
xx0300000104
A Screws
B Oil-plug
C Wrist
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
xx0200000424
xx0200000425
Location of wrist
The wrist is defined as the manipulators axis 5 and 6, This is shown in pos (A) in the figure
below.
x0300000409
A Wrist
B Upper arm
C Lower arm
D Frame
E Foot
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Lifting device, manipulator
Special toolkit
Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures may These procedures include
be required. See references to references to the tools
these procedures in the step-by- required.
step instructions below.
Location
The procedure below details how to remove the wrist from the robot upper arm.
The wrist, which includes axes 5 and 6, is a complete unit comprising drive units and
gearboxes. It is a replacement unit of complex design and should not normally be serviced
on-site. Instead it should be sent to ABB for service etc.
ABB recommends its customers to carry out only the following servicing and repair work on
the wrist.
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
x0300000104
• A : Screw
• B : Oil plug (air inlet)
• Wrist unit
2. Undo screws and remove the wrist
Location of wrist
The wrist is defined as the manipulators axis 5 and 6, This is shown in pos (A) in the figure
below.
x0200000409
A Wrist
B Upper arm
C Lower arm
D Frame
E Foot
Required equipment
Spare part
Equipment, etc. Art. no. Note
no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Spare part
Equipment, etc. Art. no. Note
no.
Grease
Lifting device, manipulator
Location
Location
The upper arm is located on top of the manipulator as shown in (A) and (B) the figure below.
The complete upper arm includes the wrist unit.
xx0200000409
Required equipment
Spare part
Equipment Art. no. Note/Illustration
no.
Lifting device, upper arm
Special tool 3HAB 9009-1
Lifting tool (chain) To be used together with lifting eye,
M12 and lifting device, upper arm.
Spare part
Equipment Art. no. Note/Illustration
no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
xx0200000436
A Cover
B KM nuts
C Screw
Removal
The procedure below details how to remove the complete upper arm.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
xx0200000435
Location
The upper arm is located on top of the manipulator as shown in (A) and (B) the figure below.
The complete upper arm includes the wrist unit.
xx0200000409
Required equipment
xx0200000436
A Cover
B KM nuts
C Screw
Reassemble
The procedure below details how to reinstall the complete upper arm.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
WARNING!
Ensure that
• - the area around the manipulator is clear as the machine can swing round as it leaves
the pallet!
• - the trolley has free movement while lifting. If the trolley gets stuck, the manipulator
is likely to fall off and can cause personal injury and damage to the manipulator!
xx0200000409
A Wrist
B Upper arm
C Lower arm
D Frame
E Robot foot
Required equipment
xx0200000439
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result
from touching them!
• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
• When replacing motors/reducers, make sure that those parts of the robot which could
move unexpectedly are mechanically blocked as specified in the individual
procedures.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.
xx0200000435
xx0200000440
7. Take off the lower arm Shown in the figure in section Lifting off the
lower arm on page 111
xx0200000409
A Wrist
B Upper arm
C Lower arm
D Frame
E Robot foot
Required equipment
Spare part
Equipment, etc. Art. no. Note
no.
Bearing Grease 3HAB 3537-1 For lubricating shaft hole
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
xx0200000441
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
WARNING!
Ensure that
• - the area around the manipulator is clear as the machine can swing round as it leaves
the pallet!
• - the trolley has free movement while lifting. If the trolley gets stuck, the manipulator
is likely to fall off and can cause personal injury and damage to the manipulator!
xx0200000442
A Tie rod
B Parallel arm
Required equipment
Spare part
Equipment, etc. Art. no. Note
no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Tie rod
xx0200000443
A Bearing Sealing
B Back up ring
C Screw, hex. socket head cap
D Locking Washer
E Bearing
Upper connection IRB 2400 5 kg
F Bearing Sealing
G Bearing
H Bearing Sealing
I Screw
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
xx0200000444
A Tie rod
B Parallel arm
Required equipment
Spare part
Equipment, etc. Art. no. Note
no.
Loctite 243
Grease
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Tie rod
xx0200000443
A Bearing Sealing
B Back up ring
C Screw, hex. socket head cap
D Locking Washer
E Bearing
Upper connection IRB 2400 5 kg
F Bearing Sealing
G Bearing
H Bearing Sealing
I Screw
Reassemble
The procedure below details how to reassemble the tie rod.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
xx0200000451
Required equipment
Spare
Equipment, etc. Art. no. Note
part. no.
Gasket 3HAB 5537-1
SMB- unit 3HAB 8413-01
Battery unit 4944 026-4
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Circuit Diagram See chapter Circuit diagram in
the Product manual, reference
information.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.
xx0200000399
A Cover plate
B Screw
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Removal, battery
The procedure below details how to remove the SMB battery.
SMB unit
xx0200000452
xx0200000451
Required equipment
Spare
Equipment, etc. Art. no. Note
part. no.
Gasket 3HAB 5537-1
SMB- unit 3HAB 8413-01
Battery unit 4944 026-4
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
SMB unit
xx0200000452
A R1.SMB1-2
B R1.SMB1-3
C R1.SMB4-6
D R2.G
E R2:SMB
xx0200000399
A Cover
B Screws
xx0200000459
A Brake release
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result
from touching them!
• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
• When replacing motors/reducers, make sure that those parts of the robot which could
move unexpectedly are mechanically blocked as specified in the individual
procedures.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.
CAUTION!
If the manipulator normally works in an inverted position, it must be removed from this
position and placed on the floor before the work detailed in this instruction may be carried
out !
xx0200000463
Required equipment
Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
NOTE!
The robot must not be in the STANDBY MODE! This applies for all types of cabling work.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result
from touching them!
• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
• When replacing motors/reducers, make sure that those parts of the robot which could
move unexpectedly are mechanically blocked as specified in the individual
procedures.
xx0200000444
A Tie rod
B Parallel arm
Required equipment
Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Special toolkit
Other tools and procedures may be These procedures include
required. See references to these references to the tools required.
procedures in the step-by-step
instructions below.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
xx0200000444
A Tie rod
B Parallel arm
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Groove ball bearing 3HAB 3643-12 61822-2RS1
Sealing V-ring 3HAB 5515-1 Acetal (POM)
Bearing grease 3HAB 3537-1 1g
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Spare
Equipment, etc. Art. no. Note
part no.
Special toolkit
Other tools and These procedures include references to
procedures may be the tools required.
required. See
references to these
procedures in the
step-by-step
instructions below.
Assembly
The procedure below details how to assemble the sealing, bearing and how do mount parallel
arm on the robot.
xx0200000450
A Parallel arm
B Sealing V- ring
C Groove ball bearing
D Screw (hex.socket head cap )
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
4.7 Motors
xx0200000465
A Cover
B Connection box
C Screw + Spring washer
D Motor axis 1
E Position mark
Required equipment
Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the Product
manual, reference information.
Removal
The procedure below details how to remove motor, axis 1.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!
xx0200000406
• A: R3.MP1
• B: R3.FB1
• C: Connection box
3. Remove the Connection box by
unscrewing its three attachment
screws and plain washers.
xx0200000465
A Cover
B Connection box
C Screws
D Motor axis 1
E Marking
F O-ring
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Gasket 3HAB 3676-1
O-ring 3HAB 3772-1
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Removal
The procedure below details how to refit motor, axis 1.
xx0200000406
• A: R3.MP1
• B: R3.FB1
• C: Connection box
7. Refit the cover of the connection box Shown in figure in sectionLocation of motor
axis 1 on page 143
xx0200000470
A Torx screw
B Cover
C Connection box
D Gasket
E Motor 2
F Screw
G O-ring
Required equipment
Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the Product
manual, reference information.
xx0200000401
• A: R3.MP2
• B: R3.FB2
• C: Connection box
3. Remove the Connection box by
unscrewing its three attachment
screws and plain washers.
4. Use a marker pen to mark out the Shown in figure in sectionLocation of motor
position of the motor axis 2 on page 145
5. Secure the upper arm before
unscrewing any of the motor
attachment screws.
xx0300000107
xx0200000470
A Torx screw
B Cover
C Connection box
D Gasket
E Motor 2
F Screw
G O-ring
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Gasket 3HAB 3676-1
O-ring 3HAB 3772-1
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Mounting tool 3HAB 7887-1
Refit motor 2
The procedure below details how to refit motor, axis 2.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
xx0200000473
xx0200000401
• A: R3.MP2
• B: R3.FB2
• C: Connection box
16. Refit the cover of the connection box. Shown in figure in sectionLocation of
motor axis 2 on page 148
17. Calibrate the robot. Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.
xx0200000471
A Torxs screw
B Cover
C Connection box
D Gasket
E Motor 2
F Screw
G O-ring
Required equipment
Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference information.
xx0200000401
• A: R3.MP3
• B: R3.FB3
• C: Connection box
3. Remove the Connection box by
unscrewing its three attachment
screws and plain washers.
xx0300000107
xx0200000471
A Torx screw
B Cover
C Connection box
D Gasket
E Motor 2
F Screw
G O-ring
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include references
may be required. See to the tools required.
references to these
procedures in the step-by-
step instructions below.
Gasket 3HAB 3676-1
O-ring 3HAB 3772-1
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Mounting tool 3HAB 7887-1
Refitt motor 3
The procedure below details how to refitt motor, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
xx0200000473
xx0200000401
• A: R3.MP3
• B: R3.FB3
• C: Connection box
16. Refitt the cover of the connection box. Shown in figure in sectionRefitting of motor,
axis 1 on page 143
17. Calibrate the robot. Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.
xx0200000476
A Torx screw
B Cover
C Connection box
D Screw
E Motor 6
F Motor 5
G Motor 4
H Gearbox
Required equipment
Spare Art.
Equipment, etc. ote
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
xx0300000063
xx0200000401
• A: R3.MP4
• B: R3.FB4
• C: Case
2. Loosen connectors R3.MP4 and Shown in figure above.
R3.FB4.
3. Remove the Connection box by
unscrewing its three attachment
screws and plain washers.
4. Use a marker pen to mark out
the position of the motors.
5. Remove the motor by
unscrewing its attachment
screws and plain washers.
WARNING! The gearbox is filled
with oil, to avoid oil from leaking
when dismounting the motors,
drain the oil from the gearbox.
6. Remove the motors by gently
lifting them straight up
(horizontal movement).
xx0200000476
A Torx screw
B Cover
C Connection box
D Screw
E Motor 6
F Motor 5
G Motor 4
H Gearbox
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
O-ring 3HAB 3772-1 3 pcs
Loctite 243 3HAB 7116-1
Bearing grease 3HAB 3537-1
Mount tool 3HAB 7887-1
Lubricating oil 1171 2016-604
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Spare
Equipment, etc. Art. no. Note
part no.
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
xx0300000005
xx0300000108
A Torx screw
B Cover
C Connection box
D Screw
E Motor 6
F Motor 5
G Motor 4
H Gearbox
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures may These procedures include
be required. See references to references to the tools
these procedures in the step-by- required.
step instructions below.
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.
xx0200000406
• A: R3.MP5
• B: R3.MP6
• C: R3.MP4
• D: R3.FB5
• E: R3.FB6
• F: R3.FB4
3. Remove the Connection box by
unscrewing its three attachment screws
and plain washers.
4. Use a marker pen to mark out the
position of the motors
xx0300000108
A Torx screw
B Cover
C Connection box
D Screw
E Motor 6
F Motor 5
G Motor 4
H Gearbox
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
O-ring 3HAB 3772-1
Loctite 243 3HAB 7116-1
Bearing grease 3HAB 3537-1
Mount tool 3HAB 7887-1
Lubricating oil 1171 2016-604
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Spare
Equipment, etc. Art. no. Note
part no.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these procedures required.
in the step-by-step instructions
below.
Reused screws may be used,
providing they are lubricated as
detailed in Screw Joints before
fitting.
Circuit Diagram 3HAC 6670-3 See chapter Circuit diagram in
the Product manual, reference
information.
xx0300000005
4.8 Gearboxes
xx0300000007
Required equipment
Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures may be These procedures include
required. See references to these references to the tools required.
procedures in the step-by-step
instructions below.
Removal
The procedure below details how to remove gearbox, axis 1-3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.
xx0300000007
Required equipment
Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures may be These procedures include
required. See references to these references to the tools required.
procedures in the step-by-step
instructions below.
Refitting
The procedure below details how to refit gearbox, axis 1-3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
Location
The drive mechanism is defined as the gears and drive belts to axes 5 and 6. This is shown in
the figure below.
xx0300000012
Required equipment
Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
Removal
The procedure below details how to remove the Drive Shaft Unit from the robot upper arm.
NOTE! ABB recommends its customers to carry out only the following servicing and repair
work on the Drive Shaft Unit.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.
xx0300000021
• A: Screws
• B: Motor screws
4. Squeeze the drive shafts together at the tip
of the tubular shaft, so they can pass
through the tube
5. Pull out the complete drive mechanism of
axes 5 and 6.
6. Undo the screws and nuts , holding the Described in section Removal of motor,
motors and remove both motors. axis 4-6;IRB 2400L on page 159.
7. Undo the screws and remove the motor
plate.
8. Remove the gear belts.
Location
The drive mechanism is defined as the gears and timing belts to axis 5 and 6. This is shown
in the figure below.
xx0300000012
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
Lifting device, manipulator
Standard toolkit The contents are defined
in section Standard toolkit
in the Product manual,
reference information!
Other tools and procedures may These procedures include
be required. See references to references to the tools
these procedures in the step-by- required.
step instructions below.
New timing belt 3HAA 2393-1 2 pcs
Mounting Tool 3HAA 7601-050
Location
The procedure below details how to remove the Drive Shaft Unit from the robot upper arm.
NOTE! ABB recommends its customers to carry out only the following servicing and repair
work on the Drive Shaft Unit.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
xx0300000021
• A: 8.3 Nm
8. Install the cabling and mount the Detailed in Refitting of motor, axis 4-6 on page
cover to motors axes 5 and 6. 162
9. Mount the wrist. Described in sectionRefitting of wrist IRB
2400/10/16 on page 96
10. Calibrate the robot. Calibration is detailed in separate calibration
manuals.
Art. no. for the manuals are specified in
section Document references in the Product
manual, reference information.
5 Calibration information
5.1. Introduction
General
This chapter includes general information about different calibration methods and details also
procedures that does not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
References
The article numbers for the Calibration manuals are listed in section Document references in
the Product manual (part 2 of 2), reference information. Article numbers for the calibration
tools are also listed in part 2 of the Product manual.
Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.
Types of calibration
Type of
Description Calibration method
calibration
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, i.e. the axes positions (angles) are (standard method)
set to 0º. or
Standard calibration data is found in the file Levelmeter calibration
calib.cfg, supplied with the robot at delivery. (alternative method)
The file identifies the correct resolver/motor
position corresponding to the robot home
position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Absolute Accuracy Based on standard calibration, but besides CalibWare
calibration positioning the robot at home position, the
(optional) Absolute Accuracy calibration also
compensates for:
• mechanical tolerances in the robot
structure
• deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies
motor positions as well as absacc-
compensation parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy
performance, the robot must be recalibrated
for Absolute Accuracy!
xx0400001197
Calibration methods
Each calibration method is detailed in separate manuals. Below is a brief description of the
methods available.
Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.
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General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using either the TPU or the FlexPendant.
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4. Select the desired axis and press Incl to include it (it will
be marked with an x) or press All to select all axes.
5. Press OK when all axes that are to be updated are marked
with an x.
CANCEL returns to the Calibration window.
Caution!
If a revolution counter is incorrectly updated, it will cause
incorrect robot positioning, which in turn may cause damage or
injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section Checking the
calibration position on page 193.
Step Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.
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Step Action
3. Tap Update revolution counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
4. Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
5. A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from
the list of axes.
6.
Caution!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 193.
General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
• Using a MoveAbsJ instruction with argument zero on all axes
• Using the Jogging window on the teach pendant
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C
Calibration position 189
calibration position, checking 193
calibration position, jog to 194
Connection of external safety devices 15
D
direction of axes 188
L
Limitation of Liability 16
N
negative directions, axes 188
P
positive directions, axes 188
R
Revolution counters 189
S
Safety, service 15
U
Updating revolution counters 189
V
Validity and responsibility 15