Abb Product Manual Procedures Irb2400 Part 2
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Product manual (part 2 of 2), reference information Articulated robot IRB 2400 - L IRB 2400 - 10 IRB 2400 - 16 M2000,M2000A, M2004
Product manual (part 2 of 2), reference information Articulated robot IRB 2400 - L IRB 2400 - 10 IRB 2400 - 16 M2000 M2000A M2004 Document ID: 3HAC 022031-001 Revision: A
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without 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 Automation Technologies AB Robotics SE-721 68 Västerås Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1 Reference information
9
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.7 Standard toolkit, IRB 2400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2 Part list
21
3 Foldouts
23
4 Circuit diagram
25
3HAC 022031-001 Revision: A
3
Overview
Overview About this manual This manual contains reference information for all procedures described in the Product manual, procedures . Usage This manual should be used during •
installation
•
maintenance work
•
repair work.
Who should read this manual? This manual is intended for: •
installation personnel
•
maintenance personnel
•
repair personnel.
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
Reference information
Useful information when performing installation, maintenance or repair work (lists of necessary tools, reference documents, safety standards).
Part list
Complete list of manipulator parts, shown in the exploded views or foldouts.
Exploded views / Foldouts
Detailed illustrations of the manipulator with reference numbers to the part list.
Circuit Diagram
Circuit Diagram of the manipulator.
References Reference
4
Document Id
3HAC 022031-001 Revision: A
Overview
Revisions Revision
Description
-
First edition. Replaces previous manuals: • Installation and Commssioning Manual • Maintenance Manual • Repair Manual, part 1 • Repair Manual, part 2. Changes made in the material from the previous manuals: • Model M2004 implemented.
A
Section Document references is completed with article numbers for calibration manuals.
3HAC 022031-001 Revision: A
5
Product documentation, M2000/M2000A
Product documentation, M2000/M2000A General The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below: Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures •
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information •
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. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: •
Installation information
•
Repair information
•
Maintenance information
In addition, spare part information is supplied for the entire option.
6
3HAC 022031-001 Revision: A
Product documentation, M2004
Product documentation, M2004 General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures •
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information •
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)
3HAC 022031-001 Revision: A
7
Product documentation, M2004
•
How to use the application
•
Examples of how to use the application
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: •
8
Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system)
3HAC 022031-001 Revision: A
1 Reference information 1.1. Introduction
1 Reference information 1.1. Introduction General This chapter includes general information, complementing the more specific information in the Product manual (part 1 of 2), procedures.
3HAC 022031-001 Revision: A
9
1 Reference information 1.2. Applicable Safety Standards
1.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: •
ISO10218, Jan. 1992, Industrial Robot Safety
•
ANSI/RIA 15.06-1999
•
ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing systems - Basic requirements
•
DIN 19258 - Interbus-S, International Standard
Standards, safety fence The following standards are applicable to the safety fence surrounding the robot cell: •
ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing systems - Basic requirements
•
prEN 999:1995
Standards, robot cell The following standards are applicable when the robot is part of a robot cell:
10
•
IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs.
•
EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.
•
EN 811 Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs.
•
Pr EN 999 Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body.
•
EN 1088 Safety of machinery - Interlocking device associated with guards principles for design and selection.
3HAC 022031-001 Revision: A
1 Reference information 1.3. Unit conversion
1.3. Unit conversion Converter table Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
3HAC 022031-001 Revision: A
39.37 in 14.5 psi
11
1 Reference information 1.4. Screw joints
1.4. Screw joints General This section details how to tighten the various types of screw joints on the robot and the controller. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue. Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed! Using other types of screws will void any warranty and may potentially cause serious damage or injury! Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions. In such cases, proceed as follows: 1. Apply lubricant to the screw thread. 2. Apply lubricant between the plain washer and screw head. 3. Tighten to the torque specified in section Tightening torque below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
Tightening torque Before tightening any screw, note the following:
12
•
Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value.
•
Use the correct tightening torque for each type of screw joint. 3HAC 022031-001 Revision: A
1 Reference information 1.4. Screw joints
•
Only use correctly calibrated torque keys.
•
Always tighten the joint by hand, and never use pneumatical tools.
•
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion.
•
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm) Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws.
Dimension
Tightening torque (Nm) Class 8.8, oillubricated
Tightening torque (Nm) Class 10.9, oillubricated
Tightening torque (Nm) Class 12.9, oillubricated
M5
6
-
-
M6
10
-
-
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension
Tightening torque (Nm) Tightening torque (Nm) Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
M10
55
66
M12
96
115
M16
235
280
3HAC 022031-001 Revision: A
13
1 Reference information 1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.
14
Dimension
Tightening torque Nm - Nominal
Tightening torque Nm - Min.
Tightening torque Nm - Max.
1/8
12
8
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
3HAC 022031-001 Revision: A
1 Reference information 1.5. Weight specifications
1.5. Weight specifications Definition In all repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model. Example Below is an example of how a weight specification is presented: CAUTION! Caution! The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
3HAC 022031-001 Revision: A
15
1 Reference information 1.6. Document references
1.6. Document references General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentation. Product specification, robot The product specification includes generic technical data. The specification listed below is the English version.
Document name
Document ID
Product specification
3HAC 9112-1
Product manuals, controller The product manuals include information about installation and service activities. The table below specifies the article numbers of the product manuals for all controller models. The part number -001 is the English version.
Document name
Document ID
Product manual, S4Cplus M2000
3HAC 021333-001
Product manual, S4Cplus M2000A
3HAC 021128-001
Product manual, IRC5 M2004
3HAC 021313-001
Operators manual The operators manual contains instructions for daily operation of robot systems. The table below specifies the article numbers of the operators manuals for different robot systems.
Document name
Document ID
Note
User’s guide (S4Cplus)
3HAC 7793-1
Contains instructions for daily operation of S4Cplus based robot systems.
Operator’s manual (IRC5)
3HAC 16590-1
Calibration manuals
16
Document name
Document ID
Note
Calibration Pendulum Instruction
3HAC 16578-1
Enclosed with the Calibration Pendulum Toolkit.
Instructions for Levelmeter calibration (alternative method)
3HAC 022907-001
Enclosed with the Levelmeter 2000.
CalibWare 2.0 Users Guide
3HAC 16090-1
Calibration tool for Absolute Accuracy calibration.
3HAC 022031-001 Revision: A
1 Reference information 1.6. Document references
Additional documentaion Document name
Document ID
External axes
3HAC 9299-1
3HAC 022031-001 Revision: A
Note
17
1 Reference information 1.7. Standard toolkit, IRB 2400
1.7. Standard toolkit, IRB 2400 General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction. Contents Qty Tool
18
1
Ring-open-end spanner 8-19mm
1
Socket head cap 2,5-17mm
1
Torx socket no:20-60
1
Torque wrench 10-100Nm
1
Small screwdriver
1
Ratchet head for torque wrench 1/2
1
Socket head cap no:5, socket 1/2"" bit L 20mm
1
Socket head cap no:6, socket 1/2"" bit L 20mm
1
Socket head cap no:8, socket 1/2"" bit L 20mm
1
Small cutting plier
3HAC 022031-001 Revision: A
1 Reference information 1.8. Lifting equipment and lifting instructions
1.8. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment. This implies that the instructions delivered with the lifting equipment should be stored for later reference.
3HAC 022031-001 Revision: A
19
1 Reference information 1.8. Lifting equipment and lifting instructions
20
3HAC 022031-001 Revision: A
1 Reference information 1.8. Lifting equipment and lifting instructions
2: Part list 2.0.1 Introduction Definitions
This chapter is an appendix to the manual and contains part lists for the manipulator. The item numbers refers to chapter Foldouts on page 35. The part list for the manipulator sometimes differ between robot versions.
3HAC 022031-001 Revision: A
21
1 Reference information 1.8. Lifting equipment and lifting instructions
2.0.2 Foot Item number refers to item number on the foldouts.Customer
Foot
cable
Itm
Qty
Name
Art. No.
Remarks
1
1
Foot
3HAC 5945-1
2
1
Gear box axes 1-3
3HAC 4795-1
3
12
Hex socket head cap screw
3HAB 3402-69
4
12
Plain washer
9ADA 312-9
5
2
Motor axes 1 and 3
3HAC 4789-1
2
Motor axes 1 and 3
3HAC 021346-001 5/10/16/kg, Yaskawa
M12x50 8.8 Gleitmo 610 Gleitmo 610
1
Motor axes 1
3HAC 021961-001 Wall ,Yaskawa
6
3
O-ring
2152 2012-434
109.5x3
7
12
Spring washer
2154 2033-9
8.4x18x2
8
4
Hex socket head cap screw
3HAB 3409-45
M8x65 12.9 Gleitmo 610
9
8
Hex socket head cap screw
3HAB 3409-37
M8x25 12.9 Gleitmo 610
Axis 4Lower Itm
arm
Qty
Name
1
Customer cable extension, axis 4 3HAC 8869-1
2400L/10, /16Upper Itm
22
13x24x2.5
Art. No.
Remarks Option 043 See below
Arm IRB 2400/10/16
Qty
Name
Art. no.
Remark
1
Lower arm
3HAC 4796-1
2400/10, /16
1
Lower arm
3HAC 4797-1
2400L
11
8
Spring washer
2154 2033-10
10.5x23x2.5
12
12
Hex socket head cap screw
3HAB 3409-50
M10x40 12.9
13
1
Spring tension plate
3HAC 2205-1
66x116x3
14
1
Damper, standard axis 2
3HAC 2180-1
15
1
Damper axis 3
3HAB 5512-1
16
4
Torx pan head roll. screw
9ADA 629-56
M6x16
17
8
Hex socket head cap screw
3HAB 3409-57
M10x60 12.9
3HAC 022031-001 Revision: A
1 Reference information 1.8. Lifting equipment and lifting instructions
Itm
Qty
Name
Art. no.
18
1
Parallel arm
3HAB 9394-1
19
2
Sealing ring
3HAB 3732-13
V-110-L 99x10.5
20
1
Groove ball bearing
3HAB 3643-12
61822-2RS1
21
2
Sealing ring
3HAB 5515-1
Acetal
26
2
Hex socket head cap screw
9ADA 183-34
M8x12
32
1
Sealing
3HAC 10089-2
33
1
Locking washer
3HAB 5523-1
SS 1914-04
34
1
Hex socket counters, head
2121 2852-449
M8x16 8.8
35
1
Sealing
3HAC 10088-4
Acetal (POM)
36
1
Motor axis 2
3HAC 4790-1
1
Motor axis 2
3HAC 021350-001 5/10/16/kg, Yaskawa
41
Lubricating oil
1171 2016-604
14 700 ml
42
Bearing grease
3HAB 3537-1
1g 1 ml Loctite 243
43
Remark
Locking liquid
3HAB 7116-1
46
1
Stop axis 1
3HAB 6687-1
48
6
Washer
2151 2082-150
49
1
Friction washer
3HAC 0447-1
50
1
Sync. mark. axis 2
3HAB 5522-1
51
1
Upper arm axes 4-6
54
2
Lock nut
2126 2851-107
M35x1.5
55
2
Shaft end
3HAB 5527-1
SS 1672-08
56
2
Hex socket head cap screw
3HAB 7700-71
M12x60 12.9
57
2
VK-cover
3HAA 2166-15
VK 62x8
60
1
Sync. market axis 3
3HAB 8385-1
62
2
Washer
3HAA 1001-134
63
9
Torx pan head roll screw
9ADA 629-43
100
1
Cable unit axes 1-3
3HAC 4791-1
102
1
Bottom plate
3HAC 2828-1
103
1
Gasket
3HAC 4554-1
104
1
Cover
3HAC 9368-1
Standard
104
1
Cover
3HAC 9362-1
Foundry
104
1
Cover
3HAC 7242-1
Wire feeder
105
1
Gasket
3HAC 3200-1
106
1
Sealing
3HAC 4113-1
107
1
Bracket
3HAB 5923-1
108
2
Holder for cable guide
3HAB 3299-1
109
1
Cable guide
3HAB 5924-1
110
1
Spring
3HAB 3662-1
111
1
Cable guide upper arm
3HAB 5928-1
112
3
Cover
3HAC 4337-1
114
1
Instruction plate
3HAC 2589-1
115
1
Serial meas. board
3HAB 3700-1
116
2
Torx pan head roll. screw
9ADA 629-45
3HAC 022031-001 Revision: A
6.1x20x2
IRB 2400/10/16
M5x16 23
1 Reference information 1.8. Lifting equipment and lifting instructions
Itm
Qty
Name
Art. no.
117
1
Battery unit
4944 026-4
118
14
Hexagon nut with flange
9ADA 290-1
M5 fzb
119
12
Cable straps, outdoor
2166 2055-3
L=208 mm
121
1
Push button unit
3HAC 0017-1
122
4
Distance bolt
2125 2052-198
123
1
Push button cover
3HAC 2744-1
125
1
Cable straps, outdoors
2166 2055-7
129
1
Signal cable SMB
3HAC 7819-1
132
2
Dust cap
3HAC 7561-3
133
1
Dust cap
3HAC 7561-4
134
15
Torx pan head screw
9ADA 618-56
M6x16 8.8
135
3
Hex socket head pan screw
9ADA 183-34
M8x12 8.8
136
8
Torx pan head roll. screw
9ADA 629-34
M4x12 Ext. conn.
137
63
Torx pan head roll. screw
9ADA 629-44
M5x12
138
6
Cable straps, outdoors
2166 2055-1
L=101 mm
139
1
Coupling
3HAB 3333-20
Locking liquid
1269 0014-412
Loctite 542 D=11.4 - 13
140
M5x15 8.9x780
141
2
Protective hood
2522 2101-8
147
3
Gasket
3HAC 4419-1
149
1
Gasket
3HAB 7160-1
Flange sealing
1234 0011-116
Loctite 574 19x0.18
150 151
Adhesive tape
1169 9198-301
152
1
Bracket
3HAB 5921-1
156
1
Parallel pin
3HAC 3785-1
157
1
Adaptor, customer cabling
3HAB 7328-1
157
1
Cover protection
3HAC 6823-1
158
1
Adaptor, power cabling
3HAB 2809-1
159
2
Protection cover
3HAC 7816-1
160
1
Sealing
3HAC 5479-3
161
1
Sealing
3HAC 5479-4
168
1
Protective hood
3HAC 3189-1
Suspended
169
2
Gasket
3HAB 9040-1
Standard
170
1
Cover
3HAC 0048-1
Profile
1866 1903-1
171
Axes 4-6Upper
24
Remark
Foundry
120 mm
Arm IRB 2400L
Itm
Qty
Name
Art. no.
Remark
45
2
Sealing
3HAC 10089-2
46
1
Damper axis 3
3HAB 5511-1
47
1
Bracket
3HAC 0001-1
48
1
Sealing
3HAC 10088-4
49
1
Hex socket counters, head
2121 2852-449
M8x16 8.8
3HAC 022031-001 Revision: A
1 Reference information 1.8. Lifting equipment and lifting instructions
Itm
Qty
Name
Art. no.
Remark
50
1
Locking washer
3HAB 5523-1
SS 1914-04 6 ml, Loctite 243
51
Locking liquid
3HAB 7116-1
52
3
Gasket
3HAC 4429-1
53
1
Cable unit axes 4-6
3HAC 9328-1
54
9
Torx pan head screw
9ADA 618-46
M5x20 8.8
55
9
Cable straps, outdoors
2166 2055-1
2.5x101
Adhesive tape
1169 9198-301
500 mm, 19x0.18
56 57
1
Cover
3HAB 6491-1
57
1
Cover with lamp unit
3HAC 2774-1
58
10
Torx pan head roll. screw
9ADA 629-44
M5x12
59
2
Hex socket head cap screw
9ADA 183-22
M6x10
60
1
Motor unit axis 6
3HAC 10602-2
1
Motor unit axis 6
3HAC 021731-001 10/16 kg, Yaskawa
1
Motor unit axis 6
3HAC 021741-001 5 kg, Yaskawa
1
1
Upper arm without wrist and motors
3HAC 1581-1
13
4
Disc spring
3HAB 3731-14
67.5x50.5x0.7
18
1
Wrist
3HAB 9439-1
Standard
18
1
Wrist
3HAB 9398-1
Foundry
19
1
O-ring
3HAB 3772-12
Nitrile rubber 126x4
20
6
Hex socket head cap screw
3HAB 3402-38
M8x30 8.8
21
15
Plain washer
9ADA 312-7
8.4x16x1.6
25
1
Motor unit axis 5
3HAC 10600-1
10 kg
1
Motor unit axis 5
3HAC 10601-1
16 kg
1
Motor unit axis 5
3HAC 021741-001 5 kg, Yaskawa
Motor unit axis 5
3HAC 021722-001 10/16 kg, Yaskawa
2
Motor unit axis 4
3HAC 10602-1
2
Motor unit axis 4
3HAC 021740-001 5 kg, Yaskawa
Gleitmo 610
26
2
Motor unit axis 4
3HAC 021353-001 10/16 kg, Yaskawa
27
3
O-ring
3HAB 3772-1
Nitrile rubber 34.2x3
28
12
Plain washer
9ADA 312-6
6.4x12x1.6
29
12
Hex socket head cap screw
3HAB 3409-26
M6x25 12.9 Gleitmo 610
30
1
Damper axis 4
3HAB 5544-1
32
4
Hex socket head cap screw
3HAB 3402-36
Lubricating oil
3HAC 0860-1
2300 ml R1/4”
M8x20 8.8 Gleitmo 610
33 34
2
Magnetic plug
2522 122-1
35
2
Sealing ring
2152 2031-6
39
Bearing grease
3HAB 3537-1
50 g
40
Flange sealing
1234 0011-116
30 ml, Loctite 574
3HAC 022031-001 Revision: A
25
Itm
Qty
Name
Art. no.
41
2
Sealing ring without dust lip
3HAC 7877-2
42
2
Taper roller bearing
3HAA 2103-15
43
1
Parallel bar
3HAC 1564-1
44
2
Spherical roller bearing
3HAA 2167-12
PartsDrive
Remark 32007 X 22206 CC
unit IRB 2400/10/16
Itm
Qty
Name
Art. no.
1
1
Tubular shaft
3HAC 0235-1
2
1
Back-up ring
3HAB 6354-1
3
1
Sealing ring
3HAB 3732-13
4
2
Ball bearing
2213 253-12
Remark
99x10.5 V-110-L 105x130x13 61821-2RSI
5
2
Cover plug
2216 264-14
IRB 2000
6
1
Housing, axis 4
3HAC 0236-1
7
2
Spacer
2159 167-61
D=115/105, T=0.05
8
4
Spacer
2159 167-62
D=115/105, T=0.1
9
1
Spacer
2159 167-63
D=115/105, T=0.5
10
1
Gear, axis 4, step 2
3HAB 3210-1
11
1
Damper, axis 4
3HAB 6356-1
12
6
Hex socket head cap screw
3HAB 3402-24
M6x16 8.8 Gleitmo 610
13
10
Plain washer
9ADA 312-6
6.4x12x1.6
14
4
Hex socket head cap screw
3HAB 3402-30
M6x45 8.8, Gleitmo 610
A2F
Drive unit axis 5-6Drive
unit IRB 2400L
Itm
Qty
Name
Art. no.
Remark
45
10
Cable straps, outdoors
2166 2055-1
2.5x101 Polyamide 6.6 black
46
1
Clamp
2166 2018-8
D=6 5562-00-04
47
1
Clamp
2166 2018-2
D=11 5562-00-07
48
1
Bracket, axes 5-6
3HAB 3230-1
49
2
Torx pan head roll screw
9ADA 629-47
50
1
Parallel bar
3HAC 1563-1
51
1
Damper, axis 3
3HAB 5511-1
M5x25 8 A2F
1 Reference information 1.8. Lifting equipment and lifting instructions
Itm
Qty
Name
Art. no.
Remark
52
2
Hex socket head cap screw
9ADA 183-22
M6x10 8.8
53
2
Spherical roller bearing
3HAA 2167-12
54
2
Sealing
3HAC 10088-4
55
1
Sealing
3HAC 10089-2
56
1
Locking washer
3HAA 2356-11
9x35x3
57
1
Hex socket head cap screw
3HAB 3402-36
M8x20 8.8 Gleitmo 610
58
1
Cable bracket upper arm
3HAB 5927-1
59
1
Cable unit axes 4-6
3HAC 9330-1
59
1
Cable unit axes 4-6
3HAC 13052-1
60
3
Gasket
3HAB 4429-1
61
1
Cable straps, outdoors
2166 2055-3
15
1
Drive unit axis 5-6
16
1
Motor unit, axis 4
3HAC 11864-1
17
4
Hex socket head cap screw
9ADA 183-14
M5x16 8.8, A2F
18
1
O-ring
2152 2011-414
44.2x3, Nitrile rubber
23
1
Gear unit, axis 4
3HAB 3380-1
24
2
Plain washer
9ADA 312-7
8.4x16x1.6, A2F
25
2
Hex socket head cap screw
9ADA 183-38
M8x30 8.8, A2F
28
1
Cover
3HAB 6355-1
30
Lubricating oil
1171 2016-604
30 ml
31
Locking liquid
3HAB 7116-1
Loctite 243
32
Locking liquid
1269 0014-413
Loctite 638
34
Flange sealing
1234 0011-116
Loctite 574
35
Bearing grease
3HAB 3537-1
Shell Retinax MS
A2F D=30/62 W=20 22206 CC Standard
Wire feeder
36
1
Wrist, 5 kg
3HAC 10814-1
Standard and Foundry
37
6
Hex socket head cap screw
3HAB 3402-25
M6x20 8.8, Gleitmo 610
38
1
Cover
3HAB 4350-1
1
Cover with lamp unit
3HAC 2743-1
Option
39
39
Torx pan head roll screw
9ADA 629-44
M5x12 8
40
1
Cover
3HAB 4405-1
43
2
Sealing ring (without dust lip)
3HAB 7877-2
D=42/55 W=8 Nitrile rubber
44
2
Taper roller bearing
3HAA 2103-15
D=35/62 W=18 32007 X
3HAC 022031-001 Revision: A
27
1 Reference information 1.8. Lifting equipment and lifting instructions
Axes 5-6Limit
Switch
Itm
Qty
Name
Art. no.
Remark
1
1
Drive shaft unit, axes 5-6
3HAC 11804-1
2
2
Motor unit axes 5-6
3HAC 11865-1
3
1
Motor plate
3HAA 2504-1
4
8
Hexagon nut
9ADA 267-5
M5 8. A2F
5
10
Hex socket head cap screw
3HAB 3402-14
M5x16 8.8 Gleitmo 610
6
10
Plain washer
9ADA 312-5
5.3x10x1. A2F
7
2
Gear belt
3HAA 2393-1
Qty
Name
Art. no.
3
Switches
1
2
Holder ring
3HAC 0305-1
2
6
Hexagon screw, button head
3HAC 0596-31
3
7
Cam, blank
3HAB 8086-1
4
24
Torx pan head screw
9ADA 618-55
5
1
Attachment plate
3HAC 0982-1
6
2
Torx pan head screw
9ADA 618-56
7
0
Position switch 1
3HAC 6447-1
7
1
Position switch 1-3
3HAC 6448-1
8
6
Hex socket head cap screw
9ADA 183-5
9
9
Shims-sheet
3HAB 7478-1
10
4
Torx pan head roll. screw
9ADA 629-42
M5x8
11
6
Clamp
2166 2018-9
D=8
12
1
Cable straps, outdoors
2166 2055-3
4.8x208
13
1
Assembly instruction
3HAB 8372-1
Incl. in the delivery.
14
2
Torx pan head screw
9ADA 618-59
M6x30.
Axis 1 Itm
28
Remark
M8x12 M6x12 M6x16
M4x16
3HAC 022031-001 Revision: A
3 Foldouts 1.8. Lifting equipment and lifting instructions
3 Foldouts
3HAC 022031-001 Revision: A
29
3 Foldouts 1.8. Lifting equipment and lifting instructions
30
3HAC 022031-001 Revision: A
4 Circuit diagram 1.8. Lifting equipment and lifting instructions
4 Circuit diagram
3HAC 022031-001 Revision: A
31
Product Manual IRB 2400
Manipulator Circuit Diagram
LIST OF CONTENTS No. of Sheets 13
Sheet no.
101
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
CONNECTION POINT LOCATIONS No. of Sheets 13
Sheet no.
102
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
BREAK UNIT No. of Sheets 13
Sheet no.
103
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
MOTOR AXIS 1 - 3 No. of Sheets 13
Sheet no.
104
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
SERIAL MEASUREMENT BOARD No. of Sheets 13
Sheet no.
105
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
MOTOR AXIS 4 - 6, 1.5 - 10 / 16 No. of Sheets 13
Sheet no.
106
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
FEED- BACK AXIS 4 - 6, 1.5 10 / 16 No. of Sheets 13
Sheet no.
107
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
MOTOR AXIS 4 - 6, 1.8 - 5 No. of Sheets 13
Sheet no.
108
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
FEED - BACK AXIS 4 - 6, 1.8 - 5 No. of Sheets 13
Sheet no.
109
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
CUSTOMER CONNECTIONS No. of Sheets 13
Sheet no.
110
3HAC 6670-3 Rev.01
Product Manual IRB 2400
INTEGRATED WIREFEED CABLING (OPTION)
Manipulator Circuit Diagram
No. of Sheets 13
Sheet no.
111
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
POS. INDICATOR AXIS 1 (OPTION) No. of Sheets 13
Sheet no.
112
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
EXTERNAL CONNECTIONS (OPTIONS) No. of Sheets 13
Sheet no.
113
3HAC 6670-3 Rev.01
3HAC 022031-001, Revision A, en
ABB Automation Technologies AB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592
Product manual (part 2 of 2), reference information Articulated robot IRB 2400 - L IRB 2400 - 10 IRB 2400 - 16 M2000 M2000A M2004 Document ID: 3HAC 022031-001 Revision: A
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without 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 Automation Technologies AB Robotics SE-721 68 Västerås Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1 Reference information
9
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.7 Standard toolkit, IRB 2400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2 Part list
21
3 Foldouts
23
4 Circuit diagram
25
3HAC 022031-001 Revision: A
3
Overview
Overview About this manual This manual contains reference information for all procedures described in the Product manual, procedures . Usage This manual should be used during •
installation
•
maintenance work
•
repair work.
Who should read this manual? This manual is intended for: •
installation personnel
•
maintenance personnel
•
repair personnel.
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
Reference information
Useful information when performing installation, maintenance or repair work (lists of necessary tools, reference documents, safety standards).
Part list
Complete list of manipulator parts, shown in the exploded views or foldouts.
Exploded views / Foldouts
Detailed illustrations of the manipulator with reference numbers to the part list.
Circuit Diagram
Circuit Diagram of the manipulator.
References Reference
4
Document Id
3HAC 022031-001 Revision: A
Overview
Revisions Revision
Description
-
First edition. Replaces previous manuals: • Installation and Commssioning Manual • Maintenance Manual • Repair Manual, part 1 • Repair Manual, part 2. Changes made in the material from the previous manuals: • Model M2004 implemented.
A
Section Document references is completed with article numbers for calibration manuals.
3HAC 022031-001 Revision: A
5
Product documentation, M2000/M2000A
Product documentation, M2000/M2000A General The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below: Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures •
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information •
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. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: •
Installation information
•
Repair information
•
Maintenance information
In addition, spare part information is supplied for the entire option.
6
3HAC 022031-001 Revision: A
Product documentation, M2004
Product documentation, M2004 General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures •
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information •
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)
3HAC 022031-001 Revision: A
7
Product documentation, M2004
•
How to use the application
•
Examples of how to use the application
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: •
8
Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system)
3HAC 022031-001 Revision: A
1 Reference information 1.1. Introduction
1 Reference information 1.1. Introduction General This chapter includes general information, complementing the more specific information in the Product manual (part 1 of 2), procedures.
3HAC 022031-001 Revision: A
9
1 Reference information 1.2. Applicable Safety Standards
1.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: •
ISO10218, Jan. 1992, Industrial Robot Safety
•
ANSI/RIA 15.06-1999
•
ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing systems - Basic requirements
•
DIN 19258 - Interbus-S, International Standard
Standards, safety fence The following standards are applicable to the safety fence surrounding the robot cell: •
ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing systems - Basic requirements
•
prEN 999:1995
Standards, robot cell The following standards are applicable when the robot is part of a robot cell:
10
•
IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs.
•
EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.
•
EN 811 Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs.
•
Pr EN 999 Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body.
•
EN 1088 Safety of machinery - Interlocking device associated with guards principles for design and selection.
3HAC 022031-001 Revision: A
1 Reference information 1.3. Unit conversion
1.3. Unit conversion Converter table Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
3HAC 022031-001 Revision: A
39.37 in 14.5 psi
11
1 Reference information 1.4. Screw joints
1.4. Screw joints General This section details how to tighten the various types of screw joints on the robot and the controller. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue. Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed! Using other types of screws will void any warranty and may potentially cause serious damage or injury! Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions. In such cases, proceed as follows: 1. Apply lubricant to the screw thread. 2. Apply lubricant between the plain washer and screw head. 3. Tighten to the torque specified in section Tightening torque below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
Tightening torque Before tightening any screw, note the following:
12
•
Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value.
•
Use the correct tightening torque for each type of screw joint. 3HAC 022031-001 Revision: A
1 Reference information 1.4. Screw joints
•
Only use correctly calibrated torque keys.
•
Always tighten the joint by hand, and never use pneumatical tools.
•
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion.
•
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm) Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws.
Dimension
Tightening torque (Nm) Class 8.8, oillubricated
Tightening torque (Nm) Class 10.9, oillubricated
Tightening torque (Nm) Class 12.9, oillubricated
M5
6
-
-
M6
10
-
-
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension
Tightening torque (Nm) Tightening torque (Nm) Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
M10
55
66
M12
96
115
M16
235
280
3HAC 022031-001 Revision: A
13
1 Reference information 1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.
14
Dimension
Tightening torque Nm - Nominal
Tightening torque Nm - Min.
Tightening torque Nm - Max.
1/8
12
8
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
3HAC 022031-001 Revision: A
1 Reference information 1.5. Weight specifications
1.5. Weight specifications Definition In all repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model. Example Below is an example of how a weight specification is presented: CAUTION! Caution! The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
3HAC 022031-001 Revision: A
15
1 Reference information 1.6. Document references
1.6. Document references General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentation. Product specification, robot The product specification includes generic technical data. The specification listed below is the English version.
Document name
Document ID
Product specification
3HAC 9112-1
Product manuals, controller The product manuals include information about installation and service activities. The table below specifies the article numbers of the product manuals for all controller models. The part number -001 is the English version.
Document name
Document ID
Product manual, S4Cplus M2000
3HAC 021333-001
Product manual, S4Cplus M2000A
3HAC 021128-001
Product manual, IRC5 M2004
3HAC 021313-001
Operators manual The operators manual contains instructions for daily operation of robot systems. The table below specifies the article numbers of the operators manuals for different robot systems.
Document name
Document ID
Note
User’s guide (S4Cplus)
3HAC 7793-1
Contains instructions for daily operation of S4Cplus based robot systems.
Operator’s manual (IRC5)
3HAC 16590-1
Calibration manuals
16
Document name
Document ID
Note
Calibration Pendulum Instruction
3HAC 16578-1
Enclosed with the Calibration Pendulum Toolkit.
Instructions for Levelmeter calibration (alternative method)
3HAC 022907-001
Enclosed with the Levelmeter 2000.
CalibWare 2.0 Users Guide
3HAC 16090-1
Calibration tool for Absolute Accuracy calibration.
3HAC 022031-001 Revision: A
1 Reference information 1.6. Document references
Additional documentaion Document name
Document ID
External axes
3HAC 9299-1
3HAC 022031-001 Revision: A
Note
17
1 Reference information 1.7. Standard toolkit, IRB 2400
1.7. Standard toolkit, IRB 2400 General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction. Contents Qty Tool
18
1
Ring-open-end spanner 8-19mm
1
Socket head cap 2,5-17mm
1
Torx socket no:20-60
1
Torque wrench 10-100Nm
1
Small screwdriver
1
Ratchet head for torque wrench 1/2
1
Socket head cap no:5, socket 1/2"" bit L 20mm
1
Socket head cap no:6, socket 1/2"" bit L 20mm
1
Socket head cap no:8, socket 1/2"" bit L 20mm
1
Small cutting plier
3HAC 022031-001 Revision: A
1 Reference information 1.8. Lifting equipment and lifting instructions
1.8. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment. This implies that the instructions delivered with the lifting equipment should be stored for later reference.
3HAC 022031-001 Revision: A
19
1 Reference information 1.8. Lifting equipment and lifting instructions
20
3HAC 022031-001 Revision: A
1 Reference information 1.8. Lifting equipment and lifting instructions
2: Part list 2.0.1 Introduction Definitions
This chapter is an appendix to the manual and contains part lists for the manipulator. The item numbers refers to chapter Foldouts on page 35. The part list for the manipulator sometimes differ between robot versions.
3HAC 022031-001 Revision: A
21
1 Reference information 1.8. Lifting equipment and lifting instructions
2.0.2 Foot Item number refers to item number on the foldouts.Customer
Foot
cable
Itm
Qty
Name
Art. No.
Remarks
1
1
Foot
3HAC 5945-1
2
1
Gear box axes 1-3
3HAC 4795-1
3
12
Hex socket head cap screw
3HAB 3402-69
4
12
Plain washer
9ADA 312-9
5
2
Motor axes 1 and 3
3HAC 4789-1
2
Motor axes 1 and 3
3HAC 021346-001 5/10/16/kg, Yaskawa
M12x50 8.8 Gleitmo 610 Gleitmo 610
1
Motor axes 1
3HAC 021961-001 Wall ,Yaskawa
6
3
O-ring
2152 2012-434
109.5x3
7
12
Spring washer
2154 2033-9
8.4x18x2
8
4
Hex socket head cap screw
3HAB 3409-45
M8x65 12.9 Gleitmo 610
9
8
Hex socket head cap screw
3HAB 3409-37
M8x25 12.9 Gleitmo 610
Axis 4Lower Itm
arm
Qty
Name
1
Customer cable extension, axis 4 3HAC 8869-1
2400L/10, /16Upper Itm
22
13x24x2.5
Art. No.
Remarks Option 043 See below
Arm IRB 2400/10/16
Qty
Name
Art. no.
Remark
1
Lower arm
3HAC 4796-1
2400/10, /16
1
Lower arm
3HAC 4797-1
2400L
11
8
Spring washer
2154 2033-10
10.5x23x2.5
12
12
Hex socket head cap screw
3HAB 3409-50
M10x40 12.9
13
1
Spring tension plate
3HAC 2205-1
66x116x3
14
1
Damper, standard axis 2
3HAC 2180-1
15
1
Damper axis 3
3HAB 5512-1
16
4
Torx pan head roll. screw
9ADA 629-56
M6x16
17
8
Hex socket head cap screw
3HAB 3409-57
M10x60 12.9
3HAC 022031-001 Revision: A
1 Reference information 1.8. Lifting equipment and lifting instructions
Itm
Qty
Name
Art. no.
18
1
Parallel arm
3HAB 9394-1
19
2
Sealing ring
3HAB 3732-13
V-110-L 99x10.5
20
1
Groove ball bearing
3HAB 3643-12
61822-2RS1
21
2
Sealing ring
3HAB 5515-1
Acetal
26
2
Hex socket head cap screw
9ADA 183-34
M8x12
32
1
Sealing
3HAC 10089-2
33
1
Locking washer
3HAB 5523-1
SS 1914-04
34
1
Hex socket counters, head
2121 2852-449
M8x16 8.8
35
1
Sealing
3HAC 10088-4
Acetal (POM)
36
1
Motor axis 2
3HAC 4790-1
1
Motor axis 2
3HAC 021350-001 5/10/16/kg, Yaskawa
41
Lubricating oil
1171 2016-604
14 700 ml
42
Bearing grease
3HAB 3537-1
1g 1 ml Loctite 243
43
Remark
Locking liquid
3HAB 7116-1
46
1
Stop axis 1
3HAB 6687-1
48
6
Washer
2151 2082-150
49
1
Friction washer
3HAC 0447-1
50
1
Sync. mark. axis 2
3HAB 5522-1
51
1
Upper arm axes 4-6
54
2
Lock nut
2126 2851-107
M35x1.5
55
2
Shaft end
3HAB 5527-1
SS 1672-08
56
2
Hex socket head cap screw
3HAB 7700-71
M12x60 12.9
57
2
VK-cover
3HAA 2166-15
VK 62x8
60
1
Sync. market axis 3
3HAB 8385-1
62
2
Washer
3HAA 1001-134
63
9
Torx pan head roll screw
9ADA 629-43
100
1
Cable unit axes 1-3
3HAC 4791-1
102
1
Bottom plate
3HAC 2828-1
103
1
Gasket
3HAC 4554-1
104
1
Cover
3HAC 9368-1
Standard
104
1
Cover
3HAC 9362-1
Foundry
104
1
Cover
3HAC 7242-1
Wire feeder
105
1
Gasket
3HAC 3200-1
106
1
Sealing
3HAC 4113-1
107
1
Bracket
3HAB 5923-1
108
2
Holder for cable guide
3HAB 3299-1
109
1
Cable guide
3HAB 5924-1
110
1
Spring
3HAB 3662-1
111
1
Cable guide upper arm
3HAB 5928-1
112
3
Cover
3HAC 4337-1
114
1
Instruction plate
3HAC 2589-1
115
1
Serial meas. board
3HAB 3700-1
116
2
Torx pan head roll. screw
9ADA 629-45
3HAC 022031-001 Revision: A
6.1x20x2
IRB 2400/10/16
M5x16 23
1 Reference information 1.8. Lifting equipment and lifting instructions
Itm
Qty
Name
Art. no.
117
1
Battery unit
4944 026-4
118
14
Hexagon nut with flange
9ADA 290-1
M5 fzb
119
12
Cable straps, outdoor
2166 2055-3
L=208 mm
121
1
Push button unit
3HAC 0017-1
122
4
Distance bolt
2125 2052-198
123
1
Push button cover
3HAC 2744-1
125
1
Cable straps, outdoors
2166 2055-7
129
1
Signal cable SMB
3HAC 7819-1
132
2
Dust cap
3HAC 7561-3
133
1
Dust cap
3HAC 7561-4
134
15
Torx pan head screw
9ADA 618-56
M6x16 8.8
135
3
Hex socket head pan screw
9ADA 183-34
M8x12 8.8
136
8
Torx pan head roll. screw
9ADA 629-34
M4x12 Ext. conn.
137
63
Torx pan head roll. screw
9ADA 629-44
M5x12
138
6
Cable straps, outdoors
2166 2055-1
L=101 mm
139
1
Coupling
3HAB 3333-20
Locking liquid
1269 0014-412
Loctite 542 D=11.4 - 13
140
M5x15 8.9x780
141
2
Protective hood
2522 2101-8
147
3
Gasket
3HAC 4419-1
149
1
Gasket
3HAB 7160-1
Flange sealing
1234 0011-116
Loctite 574 19x0.18
150 151
Adhesive tape
1169 9198-301
152
1
Bracket
3HAB 5921-1
156
1
Parallel pin
3HAC 3785-1
157
1
Adaptor, customer cabling
3HAB 7328-1
157
1
Cover protection
3HAC 6823-1
158
1
Adaptor, power cabling
3HAB 2809-1
159
2
Protection cover
3HAC 7816-1
160
1
Sealing
3HAC 5479-3
161
1
Sealing
3HAC 5479-4
168
1
Protective hood
3HAC 3189-1
Suspended
169
2
Gasket
3HAB 9040-1
Standard
170
1
Cover
3HAC 0048-1
Profile
1866 1903-1
171
Axes 4-6Upper
24
Remark
Foundry
120 mm
Arm IRB 2400L
Itm
Qty
Name
Art. no.
Remark
45
2
Sealing
3HAC 10089-2
46
1
Damper axis 3
3HAB 5511-1
47
1
Bracket
3HAC 0001-1
48
1
Sealing
3HAC 10088-4
49
1
Hex socket counters, head
2121 2852-449
M8x16 8.8
3HAC 022031-001 Revision: A
1 Reference information 1.8. Lifting equipment and lifting instructions
Itm
Qty
Name
Art. no.
Remark
50
1
Locking washer
3HAB 5523-1
SS 1914-04 6 ml, Loctite 243
51
Locking liquid
3HAB 7116-1
52
3
Gasket
3HAC 4429-1
53
1
Cable unit axes 4-6
3HAC 9328-1
54
9
Torx pan head screw
9ADA 618-46
M5x20 8.8
55
9
Cable straps, outdoors
2166 2055-1
2.5x101
Adhesive tape
1169 9198-301
500 mm, 19x0.18
56 57
1
Cover
3HAB 6491-1
57
1
Cover with lamp unit
3HAC 2774-1
58
10
Torx pan head roll. screw
9ADA 629-44
M5x12
59
2
Hex socket head cap screw
9ADA 183-22
M6x10
60
1
Motor unit axis 6
3HAC 10602-2
1
Motor unit axis 6
3HAC 021731-001 10/16 kg, Yaskawa
1
Motor unit axis 6
3HAC 021741-001 5 kg, Yaskawa
1
1
Upper arm without wrist and motors
3HAC 1581-1
13
4
Disc spring
3HAB 3731-14
67.5x50.5x0.7
18
1
Wrist
3HAB 9439-1
Standard
18
1
Wrist
3HAB 9398-1
Foundry
19
1
O-ring
3HAB 3772-12
Nitrile rubber 126x4
20
6
Hex socket head cap screw
3HAB 3402-38
M8x30 8.8
21
15
Plain washer
9ADA 312-7
8.4x16x1.6
25
1
Motor unit axis 5
3HAC 10600-1
10 kg
1
Motor unit axis 5
3HAC 10601-1
16 kg
1
Motor unit axis 5
3HAC 021741-001 5 kg, Yaskawa
Motor unit axis 5
3HAC 021722-001 10/16 kg, Yaskawa
2
Motor unit axis 4
3HAC 10602-1
2
Motor unit axis 4
3HAC 021740-001 5 kg, Yaskawa
Gleitmo 610
26
2
Motor unit axis 4
3HAC 021353-001 10/16 kg, Yaskawa
27
3
O-ring
3HAB 3772-1
Nitrile rubber 34.2x3
28
12
Plain washer
9ADA 312-6
6.4x12x1.6
29
12
Hex socket head cap screw
3HAB 3409-26
M6x25 12.9 Gleitmo 610
30
1
Damper axis 4
3HAB 5544-1
32
4
Hex socket head cap screw
3HAB 3402-36
Lubricating oil
3HAC 0860-1
2300 ml R1/4”
M8x20 8.8 Gleitmo 610
33 34
2
Magnetic plug
2522 122-1
35
2
Sealing ring
2152 2031-6
39
Bearing grease
3HAB 3537-1
50 g
40
Flange sealing
1234 0011-116
30 ml, Loctite 574
3HAC 022031-001 Revision: A
25
Itm
Qty
Name
Art. no.
41
2
Sealing ring without dust lip
3HAC 7877-2
42
2
Taper roller bearing
3HAA 2103-15
43
1
Parallel bar
3HAC 1564-1
44
2
Spherical roller bearing
3HAA 2167-12
PartsDrive
Remark 32007 X 22206 CC
unit IRB 2400/10/16
Itm
Qty
Name
Art. no.
1
1
Tubular shaft
3HAC 0235-1
2
1
Back-up ring
3HAB 6354-1
3
1
Sealing ring
3HAB 3732-13
4
2
Ball bearing
2213 253-12
Remark
99x10.5 V-110-L 105x130x13 61821-2RSI
5
2
Cover plug
2216 264-14
IRB 2000
6
1
Housing, axis 4
3HAC 0236-1
7
2
Spacer
2159 167-61
D=115/105, T=0.05
8
4
Spacer
2159 167-62
D=115/105, T=0.1
9
1
Spacer
2159 167-63
D=115/105, T=0.5
10
1
Gear, axis 4, step 2
3HAB 3210-1
11
1
Damper, axis 4
3HAB 6356-1
12
6
Hex socket head cap screw
3HAB 3402-24
M6x16 8.8 Gleitmo 610
13
10
Plain washer
9ADA 312-6
6.4x12x1.6
14
4
Hex socket head cap screw
3HAB 3402-30
M6x45 8.8, Gleitmo 610
A2F
Drive unit axis 5-6Drive
unit IRB 2400L
Itm
Qty
Name
Art. no.
Remark
45
10
Cable straps, outdoors
2166 2055-1
2.5x101 Polyamide 6.6 black
46
1
Clamp
2166 2018-8
D=6 5562-00-04
47
1
Clamp
2166 2018-2
D=11 5562-00-07
48
1
Bracket, axes 5-6
3HAB 3230-1
49
2
Torx pan head roll screw
9ADA 629-47
50
1
Parallel bar
3HAC 1563-1
51
1
Damper, axis 3
3HAB 5511-1
M5x25 8 A2F
1 Reference information 1.8. Lifting equipment and lifting instructions
Itm
Qty
Name
Art. no.
Remark
52
2
Hex socket head cap screw
9ADA 183-22
M6x10 8.8
53
2
Spherical roller bearing
3HAA 2167-12
54
2
Sealing
3HAC 10088-4
55
1
Sealing
3HAC 10089-2
56
1
Locking washer
3HAA 2356-11
9x35x3
57
1
Hex socket head cap screw
3HAB 3402-36
M8x20 8.8 Gleitmo 610
58
1
Cable bracket upper arm
3HAB 5927-1
59
1
Cable unit axes 4-6
3HAC 9330-1
59
1
Cable unit axes 4-6
3HAC 13052-1
60
3
Gasket
3HAB 4429-1
61
1
Cable straps, outdoors
2166 2055-3
15
1
Drive unit axis 5-6
16
1
Motor unit, axis 4
3HAC 11864-1
17
4
Hex socket head cap screw
9ADA 183-14
M5x16 8.8, A2F
18
1
O-ring
2152 2011-414
44.2x3, Nitrile rubber
23
1
Gear unit, axis 4
3HAB 3380-1
24
2
Plain washer
9ADA 312-7
8.4x16x1.6, A2F
25
2
Hex socket head cap screw
9ADA 183-38
M8x30 8.8, A2F
28
1
Cover
3HAB 6355-1
30
Lubricating oil
1171 2016-604
30 ml
31
Locking liquid
3HAB 7116-1
Loctite 243
32
Locking liquid
1269 0014-413
Loctite 638
34
Flange sealing
1234 0011-116
Loctite 574
35
Bearing grease
3HAB 3537-1
Shell Retinax MS
A2F D=30/62 W=20 22206 CC Standard
Wire feeder
36
1
Wrist, 5 kg
3HAC 10814-1
Standard and Foundry
37
6
Hex socket head cap screw
3HAB 3402-25
M6x20 8.8, Gleitmo 610
38
1
Cover
3HAB 4350-1
1
Cover with lamp unit
3HAC 2743-1
Option
39
39
Torx pan head roll screw
9ADA 629-44
M5x12 8
40
1
Cover
3HAB 4405-1
43
2
Sealing ring (without dust lip)
3HAB 7877-2
D=42/55 W=8 Nitrile rubber
44
2
Taper roller bearing
3HAA 2103-15
D=35/62 W=18 32007 X
3HAC 022031-001 Revision: A
27
1 Reference information 1.8. Lifting equipment and lifting instructions
Axes 5-6Limit
Switch
Itm
Qty
Name
Art. no.
Remark
1
1
Drive shaft unit, axes 5-6
3HAC 11804-1
2
2
Motor unit axes 5-6
3HAC 11865-1
3
1
Motor plate
3HAA 2504-1
4
8
Hexagon nut
9ADA 267-5
M5 8. A2F
5
10
Hex socket head cap screw
3HAB 3402-14
M5x16 8.8 Gleitmo 610
6
10
Plain washer
9ADA 312-5
5.3x10x1. A2F
7
2
Gear belt
3HAA 2393-1
Qty
Name
Art. no.
3
Switches
1
2
Holder ring
3HAC 0305-1
2
6
Hexagon screw, button head
3HAC 0596-31
3
7
Cam, blank
3HAB 8086-1
4
24
Torx pan head screw
9ADA 618-55
5
1
Attachment plate
3HAC 0982-1
6
2
Torx pan head screw
9ADA 618-56
7
0
Position switch 1
3HAC 6447-1
7
1
Position switch 1-3
3HAC 6448-1
8
6
Hex socket head cap screw
9ADA 183-5
9
9
Shims-sheet
3HAB 7478-1
10
4
Torx pan head roll. screw
9ADA 629-42
M5x8
11
6
Clamp
2166 2018-9
D=8
12
1
Cable straps, outdoors
2166 2055-3
4.8x208
13
1
Assembly instruction
3HAB 8372-1
Incl. in the delivery.
14
2
Torx pan head screw
9ADA 618-59
M6x30.
Axis 1 Itm
28
Remark
M8x12 M6x12 M6x16
M4x16
3HAC 022031-001 Revision: A
3 Foldouts 1.8. Lifting equipment and lifting instructions
3 Foldouts
3HAC 022031-001 Revision: A
29
3 Foldouts 1.8. Lifting equipment and lifting instructions
30
3HAC 022031-001 Revision: A
4 Circuit diagram 1.8. Lifting equipment and lifting instructions
4 Circuit diagram
3HAC 022031-001 Revision: A
31
Product Manual IRB 2400
Manipulator Circuit Diagram
LIST OF CONTENTS No. of Sheets 13
Sheet no.
101
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
CONNECTION POINT LOCATIONS No. of Sheets 13
Sheet no.
102
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
BREAK UNIT No. of Sheets 13
Sheet no.
103
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
MOTOR AXIS 1 - 3 No. of Sheets 13
Sheet no.
104
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
SERIAL MEASUREMENT BOARD No. of Sheets 13
Sheet no.
105
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
MOTOR AXIS 4 - 6, 1.5 - 10 / 16 No. of Sheets 13
Sheet no.
106
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
FEED- BACK AXIS 4 - 6, 1.5 10 / 16 No. of Sheets 13
Sheet no.
107
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
MOTOR AXIS 4 - 6, 1.8 - 5 No. of Sheets 13
Sheet no.
108
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
FEED - BACK AXIS 4 - 6, 1.8 - 5 No. of Sheets 13
Sheet no.
109
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
CUSTOMER CONNECTIONS No. of Sheets 13
Sheet no.
110
3HAC 6670-3 Rev.01
Product Manual IRB 2400
INTEGRATED WIREFEED CABLING (OPTION)
Manipulator Circuit Diagram
No. of Sheets 13
Sheet no.
111
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
POS. INDICATOR AXIS 1 (OPTION) No. of Sheets 13
Sheet no.
112
3HAC 6670-3 Rev.01
Product Manual IRB 2400
Manipulator Circuit Diagram
EXTERNAL CONNECTIONS (OPTIONS) No. of Sheets 13
Sheet no.
113
3HAC 6670-3 Rev.01
3HAC 022031-001, Revision A, en
ABB Automation Technologies AB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592
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