Product specification

Articulated robot
IRB 2400 - 7/1.8 IRB 2400 - 10/1.55 IRB 2400 - 16/1.55 M2004

Product specification
Articulated robot
3HAC 9112-1
Rev.H IRB 2400 - 7/1.8 IRB 2400 - 10/1.55 IRB 2400 - 16/1.55 M2004

The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABB’s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.

©Copyright 2004 ABB All right reserved. ABB Robotics SE-721 68 Västerås Sweden

Table of Contents
Overview 1 Description 5 7

1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.1.2 Different robot versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Safety/Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.3.2 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.3.3 Mounting the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.3.4 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.3.5 Mounting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.3.6 Robot tool flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4 Calibration and references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.4.1 Fine calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.4.2 Absolute Accuracy calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.6.2 Performance according to ISO 9283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1.6.3 Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1.6.4 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2 Specification of Variants and Options 35

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.1.2 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3 Accessories 43

3HAC 9112-1

Rev.H

3

H 3HAC 9112-1 .Table of Contents 4 Rev.

e: Customer Connections The specification of variant and options available Users It is intended for: • • • Product managers and Product personnel Sales and Marketing personnel Order and Customer Service personnel Contents Please see Table of Contents on page 3. 3HAC022349-001 IRC5 and M2004. safety and operating requirements The load diagrams. . 3HAC024534-001 3HAC 9112-1 Rev.The IRB 2400/L 5-kg version cancelled .07.Footnote added for “Pose accuracy” Revision G Revision H Complementary Product specifications Product specification Controller Controller Software IRC5 Robot User Documentation Description IRC5 with FlexPendant.Overview Overview About this Product specification It describes the performance of the manipulator or a complete family of manipulators in terms of: • • • • • The structure and dimensional prints The fulfilment of standards. 3HAC021785-001 RobotWare 5. the motion and the robot reach The integrated auxiliary equipments as i.Option 287-5 Wash removed .New values for Performance Acc. to ISO 9283 added .H 5 . mounting of extra equipment.M2000 cancelled. Revisions Revision Revision 6 Description .Chapter Calibration and references added .

H 3HAC 9112-1 .Overview 6 Rev.

and bearings. The robot has an open structure that is specially adapted for flexible use. The IRB 2400F/10 and IRB 2400F/16 have the FoundryPlus protection which means that the hole manipulator is IP67 classified and steam washable. See Product specification . designed specifically for manufacturing industries that use flexible robot-based automation. see Product specification . development and execution of application programs communication etc. the robot can be equipped with optional software for application support . Clean Room robots The Clean Room robots are classified for clean room class 100 according to US Federal Standard 209 or class 5 according to ISO 14644-1. and can communicate extensively with external systems. 3HAC 9112-1 Rev.1.Controller IRC5 with FlexPendant.for example gluing and arc welding.1 Structure 1. Operating system The robot is equipped with the IRC5 controller and robot control software.Controller software IRC5/RobotWare Options.H 7 .and advanced functions such as multitasking. The connectors are designed for severe environments. sensor control etc.1 Introduction General IRB 2400 is a 6-axis industrial robot. communication features network communication . For a complete description on optional software. For additional functionality.1. Foundry robots The Foundry robots are suitable for operating in harsh environments and have special surface treatment and paint for excellent corrosion protection. such as motion control.1 Description 1. Other aspects of the clean room test or other clean room requirements are not considered.1 Introduction 1 Description 1. RobotWare and BaseWare OS supports every aspect of the robot system. RobotWare. The performed clean room test has classify the air cleanliness exclusively in terms of concentration of airborne particles generated by the robot. gears and other sensitive parts are highly protected. Safety standards require a conroller to be connected to the robot.

1 Introduction Manipulator axes Axis 4 Axis 5 Axis 6 Axis 3 Axis 2 Axis 1 Figure 1 The IRB 2400 manipulator has 6 axes.1.H 3HAC 9112-1 .1 Description 1. 8 Rev.

foundry robot is required) Manipulator is clean room classified handling capacity Indicates the maximum handling capacity (kg) Manipulator weight Weight Manipulator 380 kg Other technical data Data Description Values Airborne noise level The sound pressure level out.2 Different robot versions General The IRB 2400 is available in different versions depending on its handling capacity and environment protection. floor mounting or inverted.H 9 .2 Different robot versions 1.1 Description 1.Handling capacity. to Machinery side the working space directive 89/392 EEC) 3HAC 9112-1 Rev. Environment adaption Standard Foundry Clean room Pay load 7 kg IRB 2400/L IRB 2400F/L IRB 2400CR/L Pay load 10 kg IRB 2400/10 IRB 2400F/10 IRB 2400CR/10 Pay load 16 kg IRB 2400/16 IRB 2400F/16 IRB 2400CR/16 Definition of version designation IRB 2400 Application / Version .< 70 dB (A) Leq (acc. Prefix Version Protection L F or C CR Description Long arm Manipulator adapted for use in harsh environments (e.1. Available robot versions The following robot versions are available.1.g.

1.61 .50 0. Speed [mm/s] Max.37 .67 0.2 Different robot versions Power consumption Path E1-E2-E3-E4 in the ISO Cube. maximum load. 1000 500 100 Power consumption [kW] 0.0.1 Description 1.0.H 3HAC 9112-1 . 4 10 Rev.40 .39 E 1 P2 E2 P30 P 40 P10 E E3 630 mm Figure 2 Path E1-E2-E3-E4 in the ISO Cube.46 . maximum load.44 0.0.0.

A R = 330 Figure 3 View of the manipulator from the side.2 Different robot versions Dimensions for IRB 2400/L 1225 870 150 290 360 180 65 260 855 268 176 251 138 1730 615 446 100 305 723 R = 448 C L 600 180 R = 76 444 R = 347 A 389 123 A A.H 454 11 .1. rear and above (dimensions in mm).1 Description 1. 3HAC 9112-1 Rev.

2 Different robot versions Dimensions for IRB 2400/10 and IRB 2400/16 705 135 180 1065 755 306 85 133 176 268 251 138 1564 615 180 100 305 723 R = 448 446 C L 600 R = 98 444 78 R = 347 A (163) 85 A A.1. rear and above (dimensions in mm).A 389 R = 330 Figure 4 View of the manipulator from the side.H 3HAC 9112-1 454 .1 Description 1. 12 Rev.

1 Description 1. 3HAC 9112-1 Rev.2 Safety/Standards 1. safety IEC-Standards IEC 60204-1 IEC 60529 Description Electrical equipment of industrial machines Degrees of protection provided by enclosures ISO-Standards ISO 10218 ISO 9409-1 ISO 9787 Description Manipulating industrial robots.General Safety Requirements (option) The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives. Generic immunity Manipulating industrial robots. safety related parts of control systems Electrical equipment of industrial machines EMC.1 Standards The robot conforms to the following standards: EN-Standards EN ISO 12100-1 EN ISO 12100-2 EN 954-1 EN 60204 EN 61000-6-4 (option) EN 61000-6-2 EN 775 Description Safety of machinery. coordinate systems and motions Standards ANSI/RIA R15. Generic emission EMC. terminology Safety of machinery. technical specifications Safety of machinery. safety Manipulating industrial robots. mechanical interface Manipulating industrial robots.2.1 Standards 1.H 13 .06/ 1999 (option) ANSI/UL 17401998 (option) Description Safety Requirements for Industrial Robots and Robot Systems Safety Standard for Robots and Robotic Equipment CAN/CSA Z 434-03 Industrial Robots and Robot Systems .2.

will be detected at the next MOTOR OFF/MOTOR ON operation. the electrical power supplied to the motors shuts off and the brakes engage. The enabling device consists of a switch with three positions.1 Description 1. Over-speed protection The speed of the robot is monitored by two independent computers. This complies with category 3 of EN 954-1. Reduced speed In manual mode. Safety category 3 Malfunction of a single component. It is also possible to monitor the speed of equipment mounted on the robot.2 Safety The robot is designed with absolute safety in mind.2 Safety 1. If any component fails. Selecting the operating mode The robot can be operated either manually or automatically.Part 1. MOTOR ON is then prevented and the faulty section is indicated. but to all parts of the robot.2. Safety of machinery . Three position enabling device The enabling device on the FlexPendant must be used to move the robot when in manual mode. not by any external equipment. meaning that all robot movements stop when either the enabling device is pushed fully in. Additional emergency stop buttons can be connected to the robot’s safety chain circuit. In manual mode.2. Emergency stop There is one emergency stop push button on the controller and another on the FlexPendant. The speed limitation applies not only to the TCP (Tool Center point). Safe manual movement The robot is moved using a joystick instead of the operator having to look at the FlexPendant to find the right key.). This makes the robot safer to operate. the robot can only be operated via the FlexPendant. such as a sticking relay. the speed is limited to a maximum of 250 mm/s (600 inch/min. 14 Rev. It has a dedicated safety system based on a two-channel circuit which is monitored continuously.H 3HAC 9112-1 . i. or when it is released completely.e.safety related parts of control systems .

Restricting the working space The movement of each axis can be restricted using software limits.2. Collision detection (option) In case of an unexpected mechanical disturbance like a collision. 1 second the power supplied to the motors shuts off. Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratories) tough requirements for fire safety. Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. appears. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself. Delayed safeguarded space stop A delayed stop gives a smooth stop. Axes 1-2 can also be restricted by means of mechanical stops and axis 3 by an electrically switch (option).H 15 .1 Description 1. 3HAC 9112-1 Rev. such as safety gates and light curtains. When the button is released the robot will stop. electrode sticking etc. The robot stops in the same way as at a normal program stop with no deviation from the programmed path. The hold-to-run function makes program testing safer. After approx. the robot will stop and slightly back off from its stop position. Safety lamp (option) The robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.2 Safety Safeguarded space stop The robot has a number of electrical inputs which can be used to connect external safety equipment.

can be mounted on the robot’s mounting flange (axis 6) depending on the robot version. 10 or 16 kg including payload.5 Mounting equipment and Figure 9 and Figure 10. max.H 3HAC 9112-1 .3. Position switches can be supplied on axis 1 for position indicator of manipulator.4 Load diagrams Other equipment Other equipment can be mounted on the upper arm. weight 35 kg. weight 7. Holes for mounting extra equipment. Working range The working range of axes 1-2 can be limited by mechanical stops and axis 3 by limit switches.3. weight 11 kg or 12 kg.1 Description 1.3. max.1 Introduction 1.1 Introduction General The same version of the robot can either be mounted on the floor or inverted. max. 16 Rev. An end effector.3 Installation 1.3. and on the base. see chapter 1. See section 1.

2 Operating requirements Protection standards Robot Version/Protection Standard Standard and Clean Room Manipulator IRB 2400F/L and C/L Manipulator Wrist Connectors IRB 2400F/10.2 Operating requirements 1. for short periods (not exceeding 24 hours) Temperature +5°C (+41°F) to +45°C (+113°F) -25°C (-13°F) to +55°C (+131°F) up to +70°C (+158°F) Relative humidity Description Complete robot during transportation and storage Complete robot during operation Relative humidity Max.3. Complete robot during transportation and storage. Ambient temperature Description Manipulator during operation Complete robot during transportation and storage.3. 95% at constant temperature 3HAC 9112-1 Rev.1 Description 1. F/16 Manipulator Protection standard IEC529 IP54 IP55 IP67 IP67 IP67. Steam washable Clean room standards US Federal Standard 209 ISO 14644-1 Class 100 Class 5 Explosive environments The robot must not be located or operated in an explosive environment.H 17 . 95% at constant temperature Max.

See Figure 5. load at emergency stop Force xy Force z floor mounting Force z inverted mounting Torque xy Torque z ± 1700 N + 4100 ±1100 N . load at emergency stop Force xy Force z floor mounting Force z inverted mounting Torque xy Torque z ± 2000 N + 4100 ± 1400 N .4100 ±1100 N ± 3000 Nm ± 450 Nm ± 2100 N + 4100 ± 1400 N .H 3HAC 9112-1 .4100 ± 1400 N ± 3400 Nm ± 900 Nm IRB 2400/10 and IRB 2400/16 Endurance load in operation Max.1 Description 1. IRB 2400/L Endurance load in operation Max.3.3 Mounting the manipulator Maximum load in relation to the base coordinate system.3 Mounting the manipulator 1.4100 ± 1400 N ± 3400 Nm ± 550 Nm ± 2600 N + 4100 ± 1900 N .4100 ± 1900 N ± 4000 Nm ± 900 Nm 18 Rev.3.

5 Y D = 18.1 Description 1. 210 260 48 20 Ø 0.5 (2x) B-B (A) Ø 0.A D = 35 -0 +0.3 Mounting the manipulator X B 280 B Z A 48 D = 18.3.H 19 .25 A.5 A (B) 260 (C) Figure 5 Hole configuration (dimensions in mm).039 H8 (2x) Pos A B C Description Z = center line axis 1 The same dimensions View from the bottom of the base 3HAC 9112-1 Rev.

3.H 3HAC 9112-1 .1 Description 1.4 Load diagrams 1.5 kg 2 kg 300 3 kg 200 4 kg 5 kg 6 kg 7 kg 100 L (mm) 65 100 200 300 400 Figure 6 Maximum weight permitted for load mounting on the mounting flange at different positions (center of gravity).012 kgm2 20 Rev. Description Z L J See the above diagram and the coordinate system in the Product specification .axis to the center of gravity Maximum own moment of inertia on the total handling weight = d 0.IRC5 with FlexPendant Distance in X -Y plane from Z .4 Load diagrams IRB 2400/L Z (mm) 600 1 kg 500 400 1.3.

H 21 .3.axis to the center of gravity Maximum own moment of inertia on the total handling weight = d 0. Description Z L J See the above diagram and the coordinate system in the Product specification .4 Load diagrams IRB 2400/10 Z (mm) 200 6 kg 150 8 kg 100 10 kg 12 kg 50 L (mm) 100 85 150 200 Figure 7 Maximum weight permitted for load mounting on the mounting flange at different positions (center of gravity).IRC5 with FlexPendant Distance in X -Y plane from Z .040 kgm2 3HAC 9112-1 Rev.1 Description 1.

3.1 Description 1.IRC5 with FlexPendant Distance in X -Y plane from Z .H 3HAC 9112-1 .axis to the center of gravity Maximum own moment of inertia on the total handling weight = d 0. Description Z L J See the above diagram and the coordinate system in the Product specification .4 Load diagrams IRB 2400/16 Z (mm) 200 150 10 kg 12 kg 14 kg 16 kg 100 50 L (mm) 100 85 150 200 Figure 8 Maximum weight permitted for load mounting on the mounting flange at different positions (center of gravity).060 kgm2 22 Rev.

1kg 135 150 30 170 D=200 400 470 A-A M8 (3x) R=92 Depth 16 C L 120o (3x) 38o B-B M8 (3x) R=77 Depth 16 120o (3x) Max. Pos A Description The rear side of the manipulator 3HAC 9112-1 Rev. 10kg 400 A D-D D 67 D M8 (2x) Depth 14 Max.5 Mounting equipment 1. 35 kg total C B D=50 150 38o B C C-C (A) Figure 9 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).5 Mounting equipment The robot is supplied with tapped holes on the upper arm and on the base for mounting extra equipment.1 Description 1.H 23 . IRB 2400/L 300 M5 (2x) Depth 9 37 37 62 70 (2x) A Max.3.3.

H 3HAC 9112-1 . Pos A Description The rear side of the manipulator 24 Rev. 2kg A-A Max.1 Description 1.5 Mounting equipment IRB 2400/10 and IRB 2400/16 300 A M6 (2x) M8 (3x) Depth of thread 14 400 70 35 25 110 A 65 450 177 M5 (2x) 300 100 D=240 22 78 43 90 200 Max. 10kg M8 (3x) R=92 Depth 16 38o B-B M8 (3x) R=77 Depth 16 120o (3x) Max. 35 kg total C B D=50 150 38o 120o (3x) B C C-C (A) Figure 10 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).3.

depth min 8 D=6 -0 0.1 Description 1.6 Robot tool flange IRB 2400/L A 45 o D=6 -0 H7 Ø 0.05 B M6 (4x) +0.5 +0.039H8 -0 A 7 A-A Figure 12 The mechanical interface.039 h8 B 25 +0.H D=63 -0. mounting flange (dimensions in mm). mounting flange (dimensions in mm). IRB 2400/10 and IRB 2400/16 A H7.027 +0 .012 M6 (6x) 5x 60 o 10 R=25 D=31.012 9 H8 B D=25 -0 R=20 A 90o (4x) 6 A-A Figure 11 The mechanical interface.3.3.05 B 30 o +0. 3HAC 9112-1 Rev.6 Robot tool flange 1.046 h8 +0 D=50 -0.

1 Description 1.H 3HAC 9112-1 .1 Fine calibration 1.4 Calibration and references 1. please see Operating manual .1 Fine calibration General Fine calibration is made using the Calibration Pendulum.4.4. Axis 4 Axis 5 Axis 6 Axis 3 Axis 2 Axis 1 Figure 13 All axes in zero position.Calibration Pendulum. Calibration Calibration Calibration of all axes Calibration of axis 1 and 2 Calibration of axis 1 Position All axes are in zero position Axis 1 and 2 in zero position Axis 3 to 6 in any position Axis 1 in zero position Axis 2 to 6 in any position 26 Rev.

which ensures a TCP absolute accuracy of better than ± 1 mm in the entire working range.1 Description 1.4.cfg) and a certificate that shows the performance (Birth certificate). It also includes load compensation for deflection caused by the tool and equipment.2 Absolute Accuracy calibration 1. Calibration data The user is supplied with robot calibration data (compensation parameter file. The difference between an ideal robot and a real robot without AbsAcc can typically be 8 mm. resulting from mechanical tolerances and deflection in the robot structure. The positioning will be within specified performance regardless of load. absacc. The calibration concept Absolute Accuracy (AbsAcc) is a calibration concept. Tool data from robot program is used for this purpose.2 Absolute Accuracy calibration General Requires RobotWare option Absolute Accuracy. please see Product specification Controller software IRC5 for more details. Absolute accuracy compensates for: • • Mechanical tolerances in the robot structure Deflection due to load Absolute accuracy calibration is focusing on positioning accuracy in the cartesian coordinate system for the robot.H 27 .4. 3HAC 9112-1 Rev.

70 % Within 1 mm 100 100 28 Rev. Figure 14 The Cartesian coordinate system.2 Absolute Accuracy calibration Absolute Accuracy option Absolute Accuracy option is integrated in the controller algorithms for compensation of this difference and does not need external equipment or calculation. Absolute Accuracy is a RobotWare option and includes an individual calibration of the robot (mechanical arm).H 3HAC 9112-1 .4. Absolute Accuracy is a TCP calibration in order to Reach (m) a good positioning in the Cartesian coordinate system. Production data Typical production data regarding calibration are: Positioning accuracy (mm) Robot Average IRB 2400L IRB 2400/10 IRB 2400/16 0.80 0.30 Max 0.1 Description 1.40 0.

1 Description 1. and in the unlikely event of a failure. Oil is used for the gear boxes. its modular design makes it easy to change. 3HAC 9112-1 Rev.5 Maintenance and Troubleshooting 1.H 29 . The cabling is routed for longevity. It has been designed to make it as easy to service as possible: • • • Maintenance-free AC motors are used. see Maintenance section in the Product Manual.5.5.1 Introduction General The robot requires only a minimum of maintenance during operation. Maintenance The maintenance intervals depend on the use of the robot.1 Introduction 1. Changing oil in the wrist after the first year and then every 5th year. Changing batteries every 3rd year. For detailed information on maintenance procedures. The following maintenance is required: • • • Changing filter for the drive system cooling every year.

6.H 3HAC 9112-1 . Pos A B Description Wrist center Positions at wrist center (mm) and angle (degrees) see the following table 30 Rev. Type of motion Axis 1 Rotation motion Axis 2 Arm motion Axis 3 Arm motion Axis 4 Wrist motion Axis 5 Bend motion Axis 6 Turn motion 3421 Range of movement +180° to -180° +110° to -100° +65° to -60° +185° to -185° +115° to -115° +400° to -400° (Unlimited as optional) Z Pos 1 Axis 4 Pos 0 (A) Axis 3 1702 + + Pos 6 Axis 2 Pos 5 + + + Axis 5 52 R= 1 Axis 6 2885 Pos 2 X Axis 1 Pos 3 Pos 4 1810 100 00 560 R= 570 4 R= Pos 4 (B) Figure 15 The extreme positions of the robot arm (dimensions in mm).6.1 Description 1.6 Robot Motion 1.1 Introduction IRB 2400/L The working area is the same for both floor and inverted mounting.1 Introduction 1.

6.H 31 .1 Description 1.1 Introduction Positions at wrist center (mm) and Angle (degrees) for IRB 2400/L: Position no (see Figure 15) 0 1 2 3 4 5 6 Angle Position (mm) Position (mm) (degrees) X Z Axis 2 970 404 602 1577 400 -1611 -115 1620 2298 745 -246 -403 623 1088 0 0 0 110 110 -100 -100 Angle (degrees) Axis 3 0 -60 65 -60 24.5 -60 65 3HAC 9112-1 Rev.

1 Introduction IRB 2400/10 and IRB 2400/16 The working area is the same for both floor and inverted mounting.1 Description 1. +30° to -30° for wall mounted 10 kg version. For wall mounted 10 kg version axis 1 rotation is limited to ±30º.6. 2900 Pos 1 Z Axis 4 Pos 0 (A) Axis 3 1441 + + Pos 6 Axis 2 Pos 5 + Axis 5 R= 448 + + Axis 6 2458 Pos 2 Axis 1 100 Pos 4 1550 0 40 Pos 3 393 X R= 570 R= (B) Pos 4 Figure 16 The extreme positions of the robot arm (dimensions in mm). Pos A B Description Wrist center Positions at wrist center (mm) and angle (degrees) see the following table 32 Rev. Type of motion Axis 1 Rotation motiona Axis 2 Arm motion Axis 3 Arm motion Axis 4 Wrist motion Axis 5 Bend motion Axis 6 Turn motion Range of movement +180° to -180° +110° to -100° +65° to -60° +200° to -200° (Unlimited as optional) +120° to -120° +400° to -400° (Unlimited as optional) a.H 3HAC 9112-1 .

15 0. AP (mm) Linear path accuracy.41 0.1 Description 1. RP (mm) Pose accuracy. The above values are the range of average test results from a number of robots.03 0. AT (mm) Pose stabilization time.2 Performance according to ISO 9283 Positions at wrist center (mm) and Angle (degrees) for IRB 2400/10 and IRB 2400/16: Angle Position no Position (mm) Position (mm) (degrees) (see Figure 16) X Z Axis 2 0 1 2 3 4 5 6 855 360 541 1351 400 -1350 -53 1455 2041 693 -118 -302 624 1036 0 0 0 110 110 -100 -100 Angle (degrees) Axis 3 0 -60 65 -60 18.3 -60 65 1. is the difference between the teached position (position manually modified in the cell) and the average position obtained during program execution. AP according to the ISO test above.11 0.78 0.33 0.H 33 .6.6.22 Linear path repeatability. IRB Description Pose repeatability.14 IRB 2400/10 IRB 2400/16 0.15 0.11 a.03 0.6 m/s velocity on the inclined ISO test plane with all six robot axes in motion.03 0. 3HAC 9112-1 Rev.03 0.07 0.2 Performance according to ISO 9283 General At rated load and 1. Pst (s) within 0.4 mm of the position a IRB 2400/L Values 0. RT (mm) 0.04 0.

1 Description 1. 34 Rev.3 Velocity 1.3 Velocity Axis no. 1.6.6.6. see Application Interface in chapter 2 Specification of Variants and Options.01o on each axis. For wall mounted 10 kg version Supervision is required to prevent overheating in applications with intensive and frequent movements.H 3HAC 9112-1 . 0. Resolution Approx. 1 2 3 4 5 6 IRB 2400/L 150°/s 150°/s 150°/s 360°/s 360°/s 450°/s IRB 2400/10 150°/s 90°/sa 150°/s 90°/sa 150°/s 90°/sa 360°/s 360°/s 450°/s IRB 2400/16 150°/s 150°/s 150°/s 360°/s 360°/s 450°/s a.4 Signals For more information of air and signals for extra equipment to upper arm.

For controller options.1. and for software options. see Product specification .2 Specification of Variants and Options 2.Controller IRC5 with FlexPendant.1 General 2 Specification of Variants and Options 2.1 General The different variants and options for the IRB 2400 are described below.1 Introduction 2. 3HAC 9112-1 Rev.2 Manipulator Variants Standard Option 287-4 IRB 2400/L IRB 2400/10 IRB 2400/16 Option 435-9 435-7 435-8 Foundry Option 287-3 IRB 2400F/L IRB 2400F/10 IRB 2400F/16 Clean Room Option 287-1 IRB 2400CR/L IRB 2400CR/10 IRB 2400CR/16 Manipulator color Option 209-1 209-2 209-4--192 Description The robot is painted in color ABB Orange.H 35 . The robot is painted in white color. 2. limited axis 1 rotation to ± 30° and reduced speed axis 1.1. The same numbers are used here as in the Specification form. 2 and 3 to 90°/s.1.Controller software IRC5/RobotWare. For 10 kg version. see Product specification . Mounting position Option 224-1 224-2 224-3 Description Floor mounted Inverted Wall mounteda a. The manipulator is painted with the chosen RAL-color.

one FCI UT07 14 12SH44N connector and one FCI UT07 18 23SH44N connector on the rear part of the upper arm. inner hose diameter 8 mm 36 Rev. For connection of extra equipment on the manipulator. The IRB 2400F/10 and IRB 2400F/16 have the FoundryPlus protection which means that the whole manipulator is IP67 classified and steam washable. There is an inlet (R1/4”) at the base and an outlet (R1/4”) on the upper arm. 250 mA 250 V.3. Signals Power Air 23 10 1 50 V. gears and other sensitive parts are highly protected.2 Specification of Variants and Options 2. Degree of protection as in chapter 1. The robot is labeled with “Clean Room”. 2 A Max. Description 287-1 Clean Room Application interface Air supply and signals for extra equipment to upper arm.1.2 Manipulator Protection Option 287-4 Standard 287-3 Foundry Robot adapted for foundry or other harsh environments. The connectors are designed for severe environments. The robot is labeled with “Foundry” (IRB 2400F/L) or “Foundry Plus” (IRB 2400F/10 and F/16). and bearings. there are cables integrated into the manipulator’s cabling. The manipulator is finished with a special coating.2. A hose for compressed air is also integrated into the manipulator. Robot with clean room class 100 according to US Federal Standard 209 and with the same protection as in option 287-4.H 3HAC 9112-1 . 8 bar.

4 A Connector on upper arm housing: FCI 12-pin socket UTG 614-12SN Connector on robot base: FCI 12-pin UT001412PHT Not possible on IRB 2400/10 and /16. 49 V. Not together with option 218-3. Phoenix MSTB 2. The signals are connected to 12-pole screw terminals. 500 mA Connector on upper arm housing: FCI 23-pin UTG 618-23PN Connector on robot base: FCI 23-pin socket UT001823SHT Power signals: 12 signals. if 218-6 if 16-1 a.2 Specification of Variants and Options 2. The screw terminals with internal cabling are then delivered separately to be mounted in the main robot Control Module or in another encapsulation. option 435-9. to the the controller. 300 V. 218-6 Hose and cables for connection of extra equipment are extended to the wrist on the outside of the upper arm. Connection to Option 16-2 Manipulator 16-1 Cabineta Description The signals are connected directly to the manipulator base to one 40pins Harting connector.2 Manipulator Option 218-8 Description Integrated hose and cables for connection of extra equipment on the manipulator to the rear part of the upper arm. Not possible on IRB 2400/L. 218-3 Integrated wire feed cabling Control signals: 16 signals. e.H 37 .1.5/12-ST-5. Note! In a M2004 MultiMove application additional robots have no Control Module. a PLC cabinet.08. 3HAC 9112-1 Rev.g.

Switches axis 1. 2 or 3 adjustable switches is available. and of type forced disconnect.2 Specification of Variants and Options 2. The switches are manufactured by Telemecanique or Burnstein.2 Manipulator Connection to cabinet (cable length) Option 94-1 94-2 94-3 94-4 Description 7m 15 m 22 m 30 m Safety lamp Option 213-1 Description A safety lamp with an orange fixed light can be mounted on the manipulator. Note that the switches are not recommended to be used in severe environments with sand or chips.1. Position switch Switches indicating the position of axis 1. adjustable For more information see Figure 17: Option 25-2 25-4 25-3 Description One switch Two switches Three switches (A) Figure 17 Connections of the switches Pos A Description Controller 38 Rev. A design with two stationary or 1.H 3HAC 9112-1 . The lamp is active in MOTORS ON mode. The safety lamp is required on a UL/UR approved robot.

approx.1.5. (A) Figure 18 Connections of the switches. Position switch cables are included. Switches cable lengths Only together with option 271-1: Option 273-1 273-2 273-3 273-4 Cable lengths 7m 15 m 22 m 30 m 3HAC 9112-1 Rev. this option allows access to one working zone at the same time as the robot is working in the other one. 175° each. axis 1 stationary Option 25-5 Description Two switches.2 Manipulator Two switches. Cabinet Connection on the cabinet wall.2 Specification of Variants and Options 2.H 39 . Phoenix MSTB 2. Together with external safety arrangement. Pos A Description Controller Switches connected to Option 271-2 271-1 Description Manipulator Connection on the manipulator base with one FCI 23-pin connector.08.5/12-ST. The signals are connected to 12-pole screw terminals. stationary (see Figure 18) The two switches divide the working area of axis 1 into two fixed working zones. axis 1.

140° 50° 50° 140° Figure 19 Mounting area of the stops.H 3HAC 9112-1 . option 16-2. Option 431-1 239-1 426-1 Description For the connectors on the upper arm if application interface. Option 28-1 Description Axis 1 Two extra stops for restricting the working range. For connection to position switches and connection to manipulator.1. 2 and 3 can be restricted. For the connectors on the foot if connection to manipulator. pins and sockets.2 Manipulator Connector kit Detached connectors. The kit consists of connectors. option 218-8 or option 218-6. the working range of axes 1. See Figure 19. The stops can be mounted within the area from 50° to 140°. 40 Rev.2 Specification of Variants and Options 2. Working range limit To increase the safety of the robot. suitable to the connectors for the application interface and position switches. option 271-2 and option position switch(es).

Figure 20 illustrates the mounting positions of the stops. 20° 40° 50° 80° 70° Figure 20 Mounting positions of the stops.2 Specification of Variants and Options 2.1. Option 34-1 Description Axis 3 Equipment for electrically restricting the working range in increments of 5° 3HAC 9112-1 Rev.2 Manipulator Option 32-1 Description Axis 2 Stop lugs for restricting the working range.H 41 .

H 3HAC 9112-1 .1.2 Manipulator 42 Rev.2 Specification of Variants and Options 2.

Basic software and software options for robot and PC For more information.H 43 . and Product specification .3 Accessories 3 Accessories General There is a range of tools and equipment available. Robot Peripherals • • Track Motion Motor Units 3HAC 9112-1 Rev. see Product specification .Controller IRC5 with FlexPendant.Controller software IRC5/RobotWare. specially designed for the robot.

3 Accessories 44 Rev.H 3HAC 9112-1 .

9 S safeguarded space stop. 23 robot. 27 connector kit. 13 structure. 15 safety. 27 options. 13 safety lamp. 23 permitted extra load. 14 equipment mounting. 29 manipulator colors. 33 Robot Peripherals. 9 standards. 35 overspeed protection. 20 M maintenance. 30 reduced speed. 16. 25 motion. 16. 26. 17 I installation. 14 references. 38 positioning accuracy. 18 mounting flange. 9 O operating requirements. 40 cooling device. 9 working space restricting. 36 standard. 29 service position indicator. 23 extra equipment connections. 15 humidity. 38 service. 35 variants. 40 3HAC 9112-1 Rev. 26 repeatability. 17 option Absolute Accuracy.Index A accessories. 29 V Variants. 14 enabling device. 16 L load. 15 H hold-to-run control. 30 mounting extra equipment. 36 space requirements. 28 protection foundry. 33 position switch. 36 F fire safety. 16 performance. 17 R range of movement working space. 17 troubleshooting. 9 E emergency stop. 43 robot versions. 43 air supply. 15.H 45 . 16 T temperature. 15 delayed. 14 P payload. 36 C calibration. 16 inverted robot. 18 load diagrams. 38 signal connections. 35 mechanical interface. 15. 35 W weight. 7 suspended robot. 36 protection standards. 25 N noise level.

H 3HAC 9112-1 .Index 46 Rev.

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en .ABB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592 3HAC9112-1. Revision H.