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Product specificationArticulated robot
IRB 2400/10IRB 2400/16IRB 2400/LM2004
Product specification
Articulated robot3HAC9112-1
Rev. QIRB 2400/10IRB 2400/16IRB 2400/L
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, fit-ness 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 per-mission, and contents thereof must not be imparted to a third party nor be used for any unau-thorized 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 ABRobotics Products
SE-721 68 VästeråsSweden
Table of Contents
Overview 5
1 Description 7
1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.1.2 Different robot versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.2 Safety/Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181.3.2 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191.3.3 Mounting the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.4 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231.4.2 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241.4.3 Maximum load and moment of inertia for full axis 5 movement . . . . . . . . . . . . . . . . . . . . . .281.4.4 Wrist torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1.5 Mounting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301.5.1 Robot tool flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.6 Calibration and references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341.6.1 Fine calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341.6.2 Absolute Accuracy calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
1.7 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
1.8 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381.8.2 Performance according to ISO 9283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421.8.3 Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431.8.4 Stopping distance/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431.8.5 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
2 Specification of Variants and Options 45
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452.1.2 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452.1.3 Positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512.1.4 Track Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2.2 Floor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .522.2.1 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .522.2.2 Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.3 Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .542.3.1 DressPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .542.3.2 Process equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .552.3.3 AW Safety options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .562.3.4 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
3 Accessories 59
3HAC9112-1 Rev.Q 3
Table of Contents
4 Rev.Q 3HAC9112-1
Overview
OverviewAbout 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, safety and operating requirements
• The load diagrams, mounting of extra equipment, the motion and the robot reach
• The integrated auxiliary equipments as that is: Customer Connections
• The specification of variant and options available
UsersIt is intended for:
• Product managers and Product personnel
• Sales and Marketing personnel
• Order and Customer Service personnel
ContentsPlease see Table of Contents on page 3.
Revisions
Revision Description
Revision 6 - The IRB 2400/L 5-kg version cancelled- New values for Performance Acc. to ISO 9283 added- M2000 cancelled.
Revision G - Option 287-5 Wash removed
Revision H - Chapter Calibration and references added- Footnote added for “Pose accuracy”
Revision J - Arc welding added in Specification of Variants and Options
Revision K - Changes in chapter Standards - Directions of forces
Revision L - An extended load diagram for IRB 2400/16 is added- Warranty information for Load diagrams
Revision M - Maximum load and moment of inertia for full axis 5 movement- Wrist torque
Revision N - Changes for Calibration data- Work range- Explanation of ISO values (new figure and table)- Stopping distance- Changes in chapter Specification of Variants and Options, Track Motion and Process equipment- User documentation on DVD
Revision P - General update for 9.1 release
Revision Q - Updated/corrected Clean Room classes
3HAC9112-1 Rev.Q 5
Overview
Complementary Product specifications
Product specification Description
Controller IRC5 with FlexPendant, 3HAC021785-001
Controller Software IRC5
RobotWare 5.12, 3HAC022349-001
Robot User Documen-tation
IRC5 and M2004, 3HAC024534-001
6 Rev.Q 3HAC9112-1
1 Description1.1.1 Introduction
1 Description
1.1 Structure
1.1.1 Introduction
GeneralIRB 2400 is a 6-axis industrial robot, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has an open structure that is specially adapted for flexible use, and can communicate extensively with external systems.
Foundry Plus robotsThe IRB 2400F/10 and IRB 2400F/16 have the FoundryPlus protection.The Foundry Plus option is designed for harsh environments where the robot is exposed to sprays of coolants, lubricants and metal spits that are typical for die cast-ing applications or other similar applications. The Foundry Plus robot is painted with two-component epoxy on top of a special primer for excellent corrosion protection. To further improve the corrosion protection additional rust preventive are applied to exposed areas. The entire robot is IP67 compliant according to IEC 60529 - from base to wrist, which means that the electrical compartments are virtually sealed against liquid and solid contaminants. Among other things all sensitive parts are highly protected.Foundry Plus features:
• Improved sealing to prevent damp from penetrating into cavities• Additional protection of cabling and electronics• Special covers protecting cavities• Special connectorsThe Foundry Plus robot can be cleaned with adequate washing equipment.
Clean Room robotsThe clean room robots are going through a special manufacturing and painting process and are cleaned before shipment to reduce the emission of particles to a minimum.See chapter Specification of Variants and Options for options not selectable together with Clean Room.
Operating systemThe robot is equipped with the IRC5 controller and robot control software, RobotWare RW. RobotWare RW supports every aspect of the robot system, such as
3HAC9112-1 Rev.Q 7
1 Description1.1.1 Introduction
motion control, development and execution of application programs communication etc. See Product specification - Controller IRC5 with FlexPendant.Safety standards require a conroller to be connected to the robot.For additional functionality, the robot can be equipped with optional software for application support - for example gluing and arc welding, communication features - network communication - and advanced functions such as multitasking, sensor control etc. For a complete description on optional software, see Product specification - Controller software IRC5/RobotWare Options.
8 Rev.Q 3HAC9112-1
1 Description1.1.1 Introduction
Manipulator axes
Figure 1 The IRB 2400 manipulator has 6 axes.
3HAC9112-1 Rev.Q 9
1 Description1.1.2 Different robot versions
1.1.2 Different robot versions
GeneralThe IRB 2400 is available in three versions and all versions can be mounted inverted. IRB 2400/10 can also be wall mounted.
Definition of version designationIRB 2400 / Version.
Manipulator weight
Other technical data
Robot type Handling capacity (kg) Reach (m)
IRB 2400/10 10 kg 1.55 m
IRB 2400/16 16 kg (20 kg with some limita-tions, see chapter 1.4)
1.55 m
IRB 2400/L 7 kg 1.80 m
Prefix Description
Version L Long arm
Weight
Manipulator 380 kg
Data Description Values
Airborne noise level The sound pressure level out-side the working space
< 70 dB (A) Leq (acc. to Machinery directive 89/392 EEC)
10 Rev.Q 3HAC9112-1
1 Description1.1.2 Different robot versions
Power consumptionPath E1-E2-E3-E4 in the ISO Cube, maximum load.
Figure 2 Path E1-E2-E3-E4 in the ISO Cube, maximum load.
Speed [mm/s] Power consumption [kW]
Max. 0.61 - 0.67
1000 0.46 - 0.50
500 0.40 - 0.44
100 0.37 - 0.39
3HAC9112-1 Rev.Q 11
1 Description1.1.2 Different robot versions
Dimensions for IRB 2400/L
Figure 3 View of the manipulator from the side, rear and above (dimensions in mm).
12 Rev.Q 3HAC9112-1
1 Description1.1.2 Different robot versions
Dimensions for IRB 2400/10 and IRB 2400/16
Figure 4 View of the manipulator from the side, rear and above (dimensions in mm).
3HAC9112-1 Rev.Q 13
1 Description1.2.1 Standards
1.2 Safety/Standards
1.2.1 Standards
The robot conforms to the following standards:
EN-Standards Description
EN ISO 12100-1 Safety of machinery, terminology
EN ISO 12100-2 Safety of machinery, technical specifications
EN 954-1 Safety of machinery, safety related parts of control systems
EN 60204 Electrical equipment of industrial machines
EN ISO 60204-1:2006 Safety of machinery - Electrical equipment of machines
EN ISO 10218-1:2006a
a. There is a deviation from paragraph 6.2 in that only worst case stop distances andstop times are documented.
Robots for industrial environments - Safety requirements
EN 61000-6-4 (option) EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity
IEC-Standards Description
IEC 60529 Degrees of protection provided by enclosures
ISO-Standards Description
ISO 9409-1 Manipulating industrial robots, mechanical interface
ISO 9787 Manipulating industrial robots, coordinate systems and motions
Standards Description
ANSI/RIA R15.06/1999 (option)
Safety Requirements for Industrial Robots and Robot Systems
ANSI/UL 1740-1998 (option)
Safety Standard for Robots and Robotic Equipment
CAN/CSA Z 434-03 (option)
Industrial Robots and Robot Systems - General Safety Require-ments
14 Rev.Q 3HAC9112-1
1 Description1.2.1 Standards
The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives.
Safety function Description
The Service Information System (SIS)
The service information system gathers information about the robot’s usage and determines how hard the robot is used. The usage is characterized by the speed, the rotation angles and the load of every axis.With this data collection, the service interval of every individual robot of this generation can be predicted, optimized and service activities planned ahead. The collection data is available via the FlexPendant or the network link to the robot.The Process Robot Generation is designed with absolute safety in mind. It is dedicated to actively or passively avoid collisions and offers the highest level of safety to the operators and the machines as well as the surrounding and attached equipment. These features are presented in the active and passive safety system.The time the robot is in operation (brakes released) is indicated on the FlexPendant. Data can also be monitored over network, using e.g. WebWare.
The Active Safety System Description
General The active safety system includes those software features that maintain the accuracy of the robot’s path and those that actively avoid collisions which can occur if the robot leaves the programmed path accidentally or if an obstacle is put into the robot’s path.
The Active Brake System (ABS)
All robots are delivered with an active brake system that supports the robots to maintain the programmed path in General Stop (GS), Auto Stop (AS) and Superior Stop (SS).The ABS is active during all stop modes, braking the robot to a stop with the power of the servo drive system along the programmed path. After a specific time the mechanical brakes are activated ensuring a safe stop.The stopping process is in accordance with a class 1 stop. The maximum applicable torque on the most loaded axis determines the stopping distance.In case of a failure of the drive system or a power interruption, a class 0 stop turns out. Emergency Stop (ES) is a class 0 stop. All stops (GS, AS, SS and ES) are reconfigurable.While programming the robot in manual mode, the enabling device has a class 0 stop.
3HAC9112-1 Rev.Q 15
1 Description1.2.1 Standards
The Self Tuning Performance (STP)
The Process Robot Generation is designed to run at different load configurations, many of which occur within the same program and cycle.The robot’s installed electrical power can thus be exploited to lift heavy loads, create a high axis force or accelerate quickly without changing the configuration of the robot.Consequently the robot can run in a “power mode” or a “speed mode” which can be measured in the respective cycle time of one and the same program but with different tool loads. This feature is based on QuickMoveTM.The respective change in cycle time can be measured by running the robot in NoMotionExecution with different loads or with simulation tools like RobotStudio.
The Electronically Stabilised Path (ESP)
The load and inertia of the tool have a significant effect on the path performance of a robot. The Process Robot Generation is equipped with a system to electronically stabilize the robot’s path in order to achieve the best path performance.This has an influence while accelerating and braking and consequently stabilizes the path during all motion operations with a compromise of the best cycle time. This feature is secured through TrueMoveTM.
Over-speed protection The speed of the robot is monitored by two independent computers.
Restricting the working space
The movement of each axis can be restricted using software limits.As options axes 1-2 can also be restricted by means of mechanical stops and axis 3 by an electrically switch.
Collision detection (option)
In case of an unexpected mechanical disturbance, such as a collision, electrode sticking, etc., the robot will detect the collision, stop on the path and slightly back off from its stop position, releasing tension in the tool.
The Passive Safety System Description
General The Process Robot Generation has a dedicated passive safety system that by hardware construction and dedicated solutions is designed to avoid collisions with surrounding equipment. It integrates the robot system into the surrounding equipment safely.
Compact robot arm design
The shape of the lower and upper arm system is compact, avoiding interference into the working envelope of the robot.The lower arm is shaped inward, giving more space under the upper arm to re-orientate large parts and leaving more working space while reaching over equipment in front of the robot.The rear side of the upper arm is compact, with no components projecting over the edge of the robot base even when the robot is moved into the home position.
Moveable mechanical limitation of main axes (option)
Axes 1-2 can be equipped with moveable mechanical stops, limiting the working range of every axis individually. The mechanical stops are designed to withstand a collision even under full load.
The Active Safety System Description
16 Rev.Q 3HAC9112-1
1 Description1.2.1 Standards
Electronic Position Switches (EPS) on up to 7 axes (option)
EPS offers axes position status signals, fulfilling applicable regulations for personnel safety. Five outputs can each be configured to reflect the position of a single axis or a combination of axes. For each output, the range for each included axis can be set arbitrarily.
The Internal Safety Concept Description
General The internal safety concept of the Process Robot Generation is based on a two-channel circuit that is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery - safety related parts of control Systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the FlexPendant, i.e. not by any external equipment.
Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.). The speed limitation applies not only to the TCP (Tool Center Point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the FlexPendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate.
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.
Emergency stop There is one emergency stop push button on the controller and another on the FlexPendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. 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. The robot stops the same way as at a normal program stop with no deviation from the programmed path. After approx. 1 second the power supplied to the motors is shut off.
Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. When the button is released the robot will stop. The hold-to-run function makes program testing safer.
Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratories Inc.) tough requirements for fire safety.
Safety lamp (option) As an 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.
The Passive Safety System Description
3HAC9112-1 Rev.Q 17
1 Description1.3.1 Introduction
1.3 Installation
1.3.1 Introduction
GeneralThe same version of the robot can either be mounted on the floor or inverted. An end effector, max. weight 7, 10 or 16 kg including payload, can be mounted on the robot’s mounting flange (axis 6) depending on the robot version.See section 1.4 Load diagrams.
Other equipmentOther equipment can be mounted on the upper arm, max. weight 11 kg or 12 kg, and on the base, max. weight 35 kg. Holes for mounting extra equipment, see chapter 1.5 Mounting equipment and Figure 12 and Figure 13.
Working rangeThe working range of axes 1-2 can be limited by mechanical stops and axis 3 by limit switches. Electronic Position Switches can be used on all axes for position indicator of manipulator.
18 Rev.Q 3HAC9112-1
1 Description1.3.2 Operating requirements
1.3.2 Operating requirements
Protection standards
Explosive environmentsThe robot must not be located or operated in an explosive environment.
Ambient temperature
Relative humidity
Robot Version/Protection Standard Protection standard IEC60529
Standard and Clean Room Manipulator IP54
IRB 2400F/L and C/LManipulatorWristConnectors
IP55IP67IP67
IRB 2400F/10, F/16Manipulator
IP67, Steam washable
Description Standard/Option Temperature
Manipulator during opera-tion
Standard + 5°C (41°F) to + 45°C (113°F)
For the controller Standard/Option See Product specification - Con-troller IRC5 with FlexPendant
Complete robot during transportation and storage
Standard - 25°C (-13°F) to + 55°C (131°F)
For short periods (not exceeding 24 hours)
Standard up to + 70°C (158°F)
Description Relative humidity
Complete robot during transportation and storage
Max. 95% at constant temperature
Complete robot during operation Max. 95% at constant temperature
3HAC9112-1 Rev.Q 19
1 Description1.3.3 Mounting the manipulator
1.3.3 Mounting the manipulator
Maximum load in relation to the base coordinate system. See Figure 6.
IRB 2400/L
IRB 2400/10 and IRB 2400/16
Endurance load in operation Max. load at emergency stop
Force xy ± 1700 N ± 2100 N
Force z floor mounting
+ 4100 ±1100 N + 4100 ± 1400 N
Force z inverted mounting
- 4100 ±1100 N - 4100 ± 1400 N
Torque xy ± 3000 Nm ± 3400 Nm
Torque z ± 450 Nm ± 900 Nm
Endurance load in operation Max. load at emergency stop
Force xy ± 2000 N ± 2600 N
Force z floor mounting
+ 4100 ± 1400 N + 4100 ± 1900 N
Force z inverted mounting
- 4100 ± 1400 N - 4100 ± 1900 N
Torque xy ± 3400 Nm ± 4000 Nm
Torque z ± 550 Nm ± 900 Nm
20 Rev.Q 3HAC9112-1
1 Description1.3.3 Mounting the manipulator
Figure 5 Directions of forces.
Note regarding Mxy and Fxy
The bending torque (Mxy) can occur in any direction in the XY-plane of the base coordinate system.The same applies to the transverse force (Fxy).
3HAC9112-1 Rev.Q 21
1 Description1.3.3 Mounting the manipulator
Figure 6 Hole configuration (dimensions in mm).
Pos Description
A Z = center line axis 1
B The same dimensions
C View from the bottom of the base
22 Rev.Q 3HAC9112-1
1 Description1.4.1 Introduction
1.4 Load diagrams
1.4.1 Introduction
If incorrect load data and/or loads outside load diagram is used the following parts can be damaged due to overload:
• motors
• gearboxes
• mechanical structure
It is very important to always define correct actual load data and correct payload of the robot. Incorrect definitions of load data can result in overloading of the robot.
In the robot system is the service routine LoadIdentify available, which allows the user to make an automatic definition of the tool and load, to determine correct load parameters. Please see Operating Manual - IRC5 with FlexPendant, art. No. 3HAC16590-1, for detailed information.
Robots running with incorrect load data and/or with loads outside load diagram will not be covered by the robot warranty.
3HAC9112-1 Rev.Q 23
1 Description1.4.2 Diagrams
1.4.2 Diagrams
IRB 2400/L
Figure 7 Maximum weight permitted for load mounting on the mounting flange at different positions (cen-ter of gravity).
Description
Z See the above diagram and the coordinate system in the Product specification - IRC5 with FlexPendant
L Distance in X -Y plane from Z - axis to the center of gravity
J Maximum own moment of inertia on the total handling weight = ≤ 0.012 kgm2
24 Rev.Q 3HAC9112-1
1 Description1.4.2 Diagrams
IRB 2400/10
Figure 8 Maximum weight permitted for load mounting on the mounting flange at different positions (cen-ter of gravity).
Description
Z See the above diagram and the coordinate system in the Product specification - IRC5 with FlexPendant
L Distance in X -Y plane from Z - axis to the center of gravity
J Maximum own moment of inertia on the total handling weight = ≤ 0.040 kgm2
3HAC9112-1 Rev.Q 25
1 Description1.4.2 Diagrams
IRB 2400/16
Figure 9 Maximum weight permitted for load mounting on the mounting flange at different positions (cen-ter of gravity).
Description
Z See the above diagram and the coordinate system in the Product specification - IRC5 with FlexPendant
L Distance in X -Y plane from Z - axis to the center of gravity
J Maximum own moment of inertia on the total handling weight = ≤ 0.060 kgm2
26 Rev.Q 3HAC9112-1
1 Description1.4.2 Diagrams
IRB 2400/16 Extended load diagramBelow is an extended load diagram for IRB 2400/16, payload 20 kg.
Figure 10 Maximum weight permitted for load mounting on the mounting flange at different positions (center of gravity).
No extra load on wrist, see Figure 14.
Description
Z See the above diagram and the coordinate system in the Product specification - IRC5 with FlexPendant
L Distance in X -Y plane from Z - axis to the center of gravity
J Maximum own moment of inertia on the total handling weight = ≤ 0.060 kgm2
3HAC9112-1 Rev.Q 27
1 Description1.4.3 Maximum load and moment of inertia for full axis 5 movement
1.4.3 Maximum load and moment of inertia for full axis 5 movement
GeneralTotal load given as: Mass in kg, center of gravity (Z and L) in meter and moment of inertia (Jox, Joy, Joz ) in kgm2 . L= √(X2 + Y2), see Figure 11.
Full movement of Axis 5 (±115º)5
Figure 11 Moment of inertia when full movement of axis 5.
Axis Robot Type Maximum momemt of inertia
5 IRB 2400L J5 = Mass x ((Z + 0.065)2 + L2) + max (J0x, J0y) ≤ 0.65 kgm2
6 IRB 2400L J6 = Mass x L2 + J0Z ≤ 0.31 kgm2
Axis Robot Type Maximum momemt of inertia
5 IRB 2400/10 J5 = Mass x ((Z + 0.085)2 + L2) + max (J0x, J0y) ≤ 1.15 kgm2
6 IRB 2400/10 J6 = Mass x L2 + J0Z ≤ 0.70 kgm2
Axis Robot Type Maximum momemt of inertia
5 IRB 2400/16 J5 = Mass x ((Z + 0.085)2 + L2) + max (J0x, J0y) ≤ 1.85 kgm2
6 IRB 2400/16 J6 = Mass x L2 + J0Z ≤ 1.05 kgm2
Pos Description
A Center of gravity
Description
Jox, Joy, Joz Max. moment of inertia around the X, Y and Z axes at center of gravity.
28 Rev.Q 3HAC9112-1
1 Description1.4.4 Wrist torque
1.4.4 Wrist torque
The table below shows the maximum permissible torque due to payload..
Note! The values are for reference only, and should not be used for calculating permitted load offset (position of center of gravity) within the load diagram, since those also are lim-ited by main axes torques as well as dynamic loads. Also arm loads will influence the per-mitted load diagram. For finding the absolute limits of the load diagram, please contact your local ABB organization.
Robot type Max wrist torque axis 4 and 5
Max wrist torque axis 6
Max torque valid at load
IRB 2400L 12.4 Nm 5.84 Nm 7 kg
RB 2400/10 20.6 Nm 9.81 Nm 10 kg
RB 2400/16 33.0 Nm 15.7 Nm 16 kg
3HAC9112-1 Rev.Q 29
1 Description1.4.4 Wrist torque
1.5 Mounting equipmentThe robot is supplied with tapped holes on the upper arm and on the base for mounting extra equipment.
IRB 2400/L
Figure 12 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).
Pos Description
A The rear side of the manipulator
M8 (2x)Depth 14
400
300
Max. 10kgA A
150135
CL
400 470D=2
00
170
30
Max. 1kg
A - A
67
D D
37
70 (2x)62
37
D - D
Depth 9M5 (2x)
D=50150
Max. 35 kg total
M8 (3x) R=92Depth 16
120o (3x)
B
B
B - B
38o
C - C
C
C
120o (3x)
38o
M8 (3x) R=77Depth 16
(A)
30 Rev.Q 3HAC9112-1
1 Description1.4.4 Wrist torque
IRB 2400/10 and IRB 2400/16
Figure 13 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).
Pos Description
A The rear side of the manipulator
400
300
3570
65 177
M8 (3x)Depth of thread 14
A A
M6 (2x)
110
25
100
200
300 450
D=240
Max. 2kg
A - A
M5 (2x)
22
43
Max. 10kg
78 90
38o
M8 (3x) R=77Depth 16
C - C
120o (3x)
D=50150
Max. 35 kg total
B
B
C
C(A)
M8 (3x) R=92Depth 16
120o (3x)
B - B38o
3HAC9112-1 Rev.Q 31
1 Description1.4.4 Wrist torque
IRB 2400/16 with payload 20 kg
Figure 14 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).
Pos Description
A No extra load on wrist
B The rear side of the manipulator
300
100
3570
65 177
M8 (3x)Depth of thread 14
A A
100
200
A - A Max. 10kg
90
38o
M8 (3x) R=77Depth 16
C - C
120o (3x)
D=50150
Max. 35 kg total
B
B
C
C
(B)
M8 (3x) R=92Depth 16
120o (3x)
B - B
38o
(A)
32 Rev.Q 3HAC9112-1
1 Description1.5.1 Robot tool flange
1.5.1 Robot tool flange
IRB 2400/L
Figure 15 The mechanical interface, mounting flange (dimensions in mm).
IRB 2400/10 and IRB 2400/16
Figure 16 The mechanical interface, mounting flange (dimensions in mm).
45oD=6 H7
M6 (4x)
R=20
A
A
Ø 0.05 B
(4x)90o 6
D=2
5
9
A - A
D=5
0 h
8
B
H8
+0.0
27-0
+0 -0.0
39
+0.012-0
7
D=3
1,5
D=6+0.012-0
M6 (6x)
60o
30o
A - A
A
A
R=25
Ø 0.05 B
D=6
3 h
8
B
5x
H7, depth min 8
H8
+0.0
39-0
+0 -0.0
46
10
3HAC9112-1 Rev.Q 33
1 Description1.6.1 Fine calibration
1.6 Calibration and references
1.6.1 Fine calibration
GeneralFine calibration is made using the Calibration Pendulum, please see Operating manual - Calibration Pendulum.
Figure 17 All axes in zero position.
Calibration
Calibration Position
Calibration of all axes All axes are in zero position
Calibration of axis 1 and 2 Axis 1 and 2 in zero position
Axis 3 to 6 in any position
Calibration of axis 1 Axis 1 in zero position
Axis 2 to 6 in any position
34 Rev.Q 3HAC9112-1
1 Description1.6.2 Absolute Accuracy calibration
1.6.2 Absolute Accuracy calibration
GeneralRequires RobotWare option Absolute Accuracy, please see Product specification - Controller software IRC5 for more details.
The calibration conceptAbsolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute accuracy of better than ± 1 mm in the entire working range.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. It also includes load compensation for deflection caused by the tool and equipment. Tool data from robot program is used for this purpose. The positioning will be within specified performance regardless of load.
Calibration dataThe user is supplied with robot calibration data (compensation parameters saved on the manipulator SMB) and a certificate that shows the performance (Birth certifi-cate). 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.If there is a difference, at first start-up, between calibration data in controller and the robot SMB, correct by copying data from SMB to controller.
3HAC9112-1 Rev.Q 35
1 Description1.6.2 Absolute Accuracy calibration
Absolute Accuracy optionAbsolute 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).Absolute Accuracy is a TCP calibration in order to Reach (m) a good positioning in the Cartesian coordinate system.
Figure 18 The Cartesian coordinate system.
Production dataTypical production data regarding calibration are:
RobotPositioning accuracy (mm)
Average Max % Within 1 mm
IRB 2400L 0,40 0,80 100
IRB 2400/10IRB 2400/16
0,30 0,70 100
36 Rev.Q 3HAC9112-1
1 Description1.7.1 Introduction
1.7 Maintenance and Troubleshooting
1.7.1 Introduction
GeneralThe robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible:
• Maintenance-free AC motors are used.
• Oil is used for the gear boxes.
• The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change.
The following maintenance is required:• Changing filter for the drive system cooling every year.
• Changing batteries every 3rd year.
• Changing oil in the wrist after the first year and then every 5th year.
MaintenanceThe maintenance intervals depend on the use of the robot. For detailed information on maintenance procedures, see Maintenance section in the Product Manual.
3HAC9112-1 Rev.Q 37
1 Description1.8.1 Introduction
1.8 Robot Motion
1.8.1 Introduction
IRB 2400/LThe working area is the same for both floor and inverted mounting.
Type of motion Range of movement
Axis 1 Rotation motion +180° to -180°
Axis 2 Arm motion +110° to -100°
Axis 3 Arm motion +65° to -60°
Axis 4 Wrist motion +185° to -185°
Axis 5 Bend motion +115° to -115°
Axis 6 Turn motion +400° to -400° +300 rev.a to -300 rev. Max.b
a. rev. = Revolutionsb. The default working range for axis 6 can be extended by changing parameter val-
ues in the software.Option 610-1 “Independent axis” can be used for resetting the revolution counterafter the axis has been rotated (no need for “rewinding” the axis).
38 Rev.Q 3HAC9112-1
1 Description1.8.1 Introduction
Figure 19 The extreme positions of the robot arm (dimensions in mm).
Positions at wrist center (mm) and Angle (degrees) for IRB 2400/L:
Pos Description
A Wrist center
B Positions at wrist center (mm) and angle (degrees) see the following table
Position no (see Figure 19)
Position (mm) X
Position (mm) Z
Angle (degrees) Axis 2
Angle (degrees) Axis 3
0 970 1620 0 0
1 404 2298 0 -60
2 602 745 0 65
3 1577 -246 110 -60
4 400 -403 110 24.5
5 -1611 623 -100 -60
6 -115 1088 -100 65
R=570R=40
0
Pos 4
Pos 4
Pos 5
Pos 6
Pos 2
Pos 1
Pos 3
R=521
+++
Axis 4Axis 3
Axis 5 Axis 6
Axis 2
Axis 1
100
1810
1702
3421
2885
560
X
Z
+
Pos 0 (A)
+
(B)
3HAC9112-1 Rev.Q 39
1 Description1.8.1 Introduction
IRB 2400/10 and IRB 2400/16The working area is the same for both floor and inverted mounting.For wall mounted 10 kg version axis 1 rotation is limited to ±30º.
Type of motion Range of movement
Axis 1 Rotation motiona
a. +30° to -30° for wall mounted 10 kg version.
+180° to -180°
Axis 2 Arm motion +110° to -100°
Axis 3 Arm motion +65° to -60°
Axis 4 Wrist motion +200° to -200° (Unlimited as optional)
Axis 5 Bend motion +120° to -120°
Axis 6 Turn motion +400° to -400° +250 rev.b to -250 rev. Max.c
b. rev. = Revolutionsc. The default working range for axis 6 can be extended by changing parameter values in
the software.Option 610-1 “Independent axis” can be used for resetting the revolution counter afterthe axis has been rotated (no need for “rewinding” the axis).
40 Rev.Q 3HAC9112-1
1 Description1.8.1 Introduction
Figure 20 The extreme positions of the robot arm (dimensions in mm).
Positions at wrist center (mm) and Angle (degrees) for IRB 2400/10 and IRB 2400/16:
Pos Description
A Wrist center
B Positions at wrist center (mm) and angle (degrees) see the following table
Position no (see Figure 20)
Position (mm) X
Position (mm) Z
Angle (degrees) Axis 2
Angle (degrees) Axis 3
0 855 1455 0 0
1 360 2041 0 -60
2 541 693 0 65
3 1351 -118 110 -60
4 400 -302 110 18.3
5 -1350 624 -100 -60
6 -53 1036 -100 65
Pos 4
Pos 5
Pos 6
Pos 2
Axis 3
Axis 5 Axis 6
Axis 2
Pos 3
+ + ++
Axis 4
+R=448
Pos 1
Axis 1
1441
100
1550
393
2458
2900
X
Z Pos 0 (A)
R=570R=40
0
Pos 4(B)
3HAC9112-1 Rev.Q 41
1 Description1.8.2 Performance according to ISO 9283
1.8.2 Performance according to ISO 9283
GeneralAt rated load and 1.6 m/s velocity on the inclined ISO test plane with all six robot axes in motion.The figures for AP, RP, AT and RT are mesured according to Figure 21.
Figure 21 Explanation of ISO values.
The above values are the range of average test results from a number of robots.
Pos Description Pos Description
A Programmed position E Programmed path
B Mean position at program execution D Actual path at program execution
AP Mean distance from programmed position
AT Max deviation from E
RP Tolerance of posiotion B at repeated positioning
RT Tolerance of the path at repeated program execution
IRB IRB 2400/L IRB 2400/10 IRB 2400/16
Description Values
Pose repeatability, RP (mm) 0.07 0.03 0.03
Pose accuracy, APa (mm)
a. AP according to the ISO test above, is the difference between the teached position(position manually modified in the cell) and the average position obtained duringprogram execution.
0.04 0.03 0.03
Linear path repeatability, RT (mm) 0.11 0.11 0.15
Linear path accuracy, AT (mm) 0.78 0.33 0.41
Pose stabilization time, Pst (s) within 0.4 mm of the position
0.14 0.15 0.22
42 Rev.Q 3HAC9112-1
1 Description1.8.3 Velocity
1.8.3 Velocity
Supervision is required to prevent overheating in applications with intensive and frequent movements.
ResolutionApprox. 0.01o on each axis.
1.8.4 Stopping distance/time
Stopping distance/time for emergency stop (category 0), program stop (category 1) and at mains power supply failure at max speed, max streched out and max load, categories according to EN 60204-1. All results are from tests on one moving axis. All stop distances are valid for floor mounted robot, without any tilting.
Axis no. IRB 2400/L IRB 2400/10 IRB 2400/16
1 150°/s 150°/s90°/sa
a. For wall mounted 10 kg version
150°/s
2 150°/s 150°/s90°/sa
150°/s
3 150°/s 150°/s90°/sa
150°/s
4 360°/s 360°/s 360°/s
5 360°/s 360°/s 360°/s
6 450°/s 450°/s 450°/s
Robot TypeCategory 0 Category 1 Main power failure
Axis A B A B A B
IRB 2400L 1 35.2 0.47 59 0.70 46.2 0.54
2 13.9 0.18 26.2 0.35 22.1 0.24
3 10.9 0.15 26.4 0.30 21.4 0.21
Robot TypeCategory 0 Category 1 Main power failure
Axis A B A B A B
IRB 2400/10 1 39.7 0.52 43.3 0.55 51.4 0.60
2 13.5 0.18 16.4 0.19 23.7 0.25
3 16.3 0.22 18.7 0.24 26.8 0.29
3HAC9112-1 Rev.Q 43
1 Description1.8.5 Signals
1.8.5 Signals
Robot TypeCategory 0 Category 1 Main power failure
Axis A B A B A B
IRB 2400/16 1 48.4 0.62 71.0 0.88 56.1 0.67
2 16.8 0.21 28.8 0.36 23.6 0.26
3 24.9 0.30 37.9 0.44 32.3 0.35
Description
A Distance in degrees
B Stop time (s)
For more information of air and signals for extra equipment to upper arm, see Application Interface in chapter 2 Specification of Variants and Options.
44 Rev.Q 3HAC9112-1
2 Specification of Variants and Options2.1.1 General
2 Specification of Variants and Options
2.1 Introduction
2.1.1 General
The different variants and options for the IRB 2400 are described below.The same numbers are used here as in the Specification form. For controller options, see Product specification - Controller IRC5 with FlexPendant, and for software options, see Product specification - Controller software IRC5/RobotWare.
2.1.2 Manipulator
Variants
Manipulator color
Option IRB Type Handling capacity (kg) / Reach (m)
435-7 IRB 2400/10 10/1.55
435-8 IRB 2400/16 16 (20 kg with some limitations, see chapter 1.4)/1.55
435-9 IRB 2400/L 7/1.80
Option Description
209-1 The robot is painted in color ABB Orange.
209-2 The robot is painted in white color.
209-4--192 The manipulator is painted with the chosen RAL-color.
3HAC9112-1 Rev.Q 45
2 Specification of Variants and Options2.1.2 Manipulator
Protection
Mounting position
Option Description
287-4 Standard
287-3 FoundryPlus
The Foundry Plus option is designed for harsh environments where the robot is exposed to sprays of coolants, lubricants and metal spits that are typical for die casting applications or other similar applica-tions. The Foundry Plus robot is painted with two-component epoxy on top of a special primer for excellent corrosion protection. To further improve the corrosion protection additional rust preven-tive are applied to exposed areas. The entire robot is IP67 compliant according to IEC 60529 - from base to wrist, which means that the electrical compartments are virtually sealed against liquid and solid contaminants. Among other things all sensitive parts are highly protected.Foundry Plus features:
• Improved sealing to prevent damp from penetrating into cavities
• Additional protection of cabling and electronics• Special covers protecting cavities• Special connectorsThe Foundry Plus robot can be cleaned with adequate washing equipment.The robot is labeled with “Foundry” (IRB 2400F/L) or “Foundry Plus” (IRB 2400F/10 and F/16).
287-1 Clean Room
The robot is labeled with “Clean Room”.The following options are NOT selectable together with option 287-1:
• 435-2 IRB 2400L• 218-6 At upper arm axis 4
The robot has special paint quality and is always in white color
Option Description
224-1 Floor mounted
224-2 Inverted
224-3 Wall mounteda
a. For 10 kg version, limited axis 1 rotation to ± 30° and reduced speed axis 1, 2 and 3 to 90°/s.
46 Rev.Q 3HAC9112-1
2 Specification of Variants and Options2.1.2 Manipulator
Application interfaceAir supply and signals for extra equipment to upper arm.For connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling, one FCI UT07 14 12SH44N connector and one FCI UT07 18 23SH44N connector on the rear part of the upper arm.A hose for compressed air is also integrated into the manipulator. There is an inlet (R1/4”) at the base and an outlet (R1/4”) on the upper arm.
Signals 23 50 V, 250 mA
Power 10 250 V, 2 A
Air 1 Max. 8 bar, inner hose diameter 8 mm
3HAC9112-1 Rev.Q 47
2 Specification of Variants and Options2.1.2 Manipulator
Application interface connection to
Connector kitDetached connectors, suitable to the connectors for the application interface and position switches.The kit consists of connectors, pins and sockets.
Option Description
218-8 Integrated hose and cables for connection of extra equipment on the manipulator to the rear part of the upper arm.
218-6 Hose and cables for connection of extra equipment are extended to the wrist on the outside of the upper arm. Not possible on IRB 2400/L, option 435-9.
Option Description
16-1 Cabineta
a. Note! In a M2004 MultiMove application additional robots have no ControlModule. The screw terminals with internal cabling are then delivered separately tobe mounted in the main robot Control Module or in another encapsulation, forexample a PLC cabinet.
The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, to the the controller.Not together with option 218-3.
Option Description
431-1 For the connectors on the upper arm if application interface, option 218-8 or option 218-6.
239-1 For the connectors on the foot if connection to manipulator, option 16-2.
426-1 For connection to position switches and connection to manipulator, option 271-2 and option position switch(es).
48 Rev.Q 3HAC9112-1
2 Specification of Variants and Options2.1.2 Manipulator
Safety lamp
Electronic Position Switches (EPS)The mechanical position switches indicating the position of the three main axes are replaced with electronic position switches for up to 7 axes, for increased flexibility and robustness. For more detailed information see Product specification - IRC5 with FlexPendant and Application Manual EPS, art. No. 3HAC027709-001.
Option Description
213-1 A safety lamp with an orange fixed light can be mounted on the manipulator.The lamp is active in MOTORS ON mode.The safety lamp is required on a UL/UR approved robot.
3HAC9112-1 Rev.Q 49
2 Specification of Variants and Options2.1.2 Manipulator
Working range limit - axis 1To increase the safety of the robot, the working range of axis 1 can be restricted.
Figure 22 Mounting area of the stops, axis 1.
Working range limit - axis 2To increase the safety of the robot, the working range of axis 2 can be restricted.
Figure 23 Mounting positions of the stops, axis 2.
Option Description
28-1 Axis 1Two extra stops for restricting the working range. The stops can be mounted within the area from 50° to 140°. See Figure 22.
Option Description
32-1 Axis 2Stop lugs for restricting the working range. Figure 23 illustrates the mounting positions of the stops.
50 Rev.Q 3HAC9112-1
2 Specification of Variants and Options2.1.3 Positioners
Working range limit - axis 3To increase the safety of the robot, the working range of axis 3 can be restricted.
2.1.3 Positioners
GeneralRegarding positioners, see Product Specification 3HAC028283-001.
2.1.4 Track Motion
Track Motion type
Additional travel length
Example of ordering a track motion RTT, with a requested travel length of 7.5 m:
In this case, option 1000-5 specify a track motion with a travel length of 1.7 m, option 1001-1 adds 6 meters to that, ending up with a total travel length of 7.7 m.
Option Description
34-1 Axis 3Equipment for electrically restricting the working range in increments of 5°
Option Type Description
1000-5 no AW For IRB 1600/2400 robot, with a travel length of 1.7 m. For for example material handling robot.
1000-6 for AW For IRB 1600/2400 robot, with a travel length of 1.7 m. For AW robot with Marthon-pac or Bobbin holder.
Option Description Note
1001-1 (1-18) Add travel length
Chose additional travel length in meter, above the min. length under Track Motion Type.The selection 1 adds 1m travel length, 2 adds 2m travel length and so on.......
1000-5 RTT with BobbinTrack Motion Type
1001-1 Add travel length6
3HAC9112-1 Rev.Q 51
2 Specification of Variants and Options2.2.1 Manipulator
Warranty
2.2 Floor cables
2.2.1 Manipulator
Manipulator cable length
Connection of Parallel communication
Option Type Description
438-1 Standard Warranty Standard warranty is 18 months (1 1/2 years)
438-2 Standard + 12 months 18 + 12 months (2 1/2 years)
438-4 Standard + 18 months 18 + 18 months (3 years)
438-5 Standard + 24 months 18 + 24 months (3 1/2 years)
438-6 Standard + 6 months 18 + 6 months (2 years)
438-8 Stock Warranty Maximum 6 months postponed warranty starting from shipment date ABB Robotics Production unit (PRU) + Option 438-1. Warranty commences automatically after 6 months or from activation date of standard warranty. (See ABB Robotics BA Warranty Rules).
Option Lengths
210-2 7 m
210-3 15 m
210-4 22 m
210-5 30 m
Option Lengths
94-1 7 m
94-2 15 m
94-3 22 m
94-4 30 m
52 Rev.Q 3HAC9112-1
2 Specification of Variants and Options2.2.2 Positioner
2.2.2 Positioner
Positioner cable 1
Positioner cable 2
Positioner cable type
Weld return cable
Return cable
Option Lengths
1067-1 7 m
1067-2 10 m (Standard length)
1067-3 15 m
Option Lengths
1068-1 7 m
1068-2 10 m (Standard length)
1068-3 15 m
Option Type Description
1048-1 Flexible Only available with one or two MTC 250/500/750/2000/5000
Option Lengths
1056-1 7 m
1056-2 7 m x 2
1056-3 10 m
1056-4 10 m x 2
1056-5 15 m
1056-6 15 m x 2
Option Type Description
1057-1 OKC T-connection Choose quantity, 1-2
3HAC9112-1 Rev.Q 53
2 Specification of Variants and Options2.3.1 DressPack
2.3 Process
2.3.1 DressPack
Welding torch package
Process module
Installation kit
Option Description
878-2 Self cooled torch, iSTM-ABIROB A 22 degrees
878-3 Water cooled torch, iSTM-ABIROB W 22 degrees
Option Type Description
768-1 Empty cabinet small
See Product Specification - Controller IRC5 with FlexPendant, chapter 2.2.1
768-2 Empty cabinet large See Product Specification - Controller IRC5 with FlexPendant, chapter 2.2.1
768-5 AWC / WeldGuide Only together with AristoMig 4000i/5000i, MigRob and TPS power sources.
Option Type Description
715-1 Installation kit See Product Specification - Controller IRC5 with FlexPendant, chapter 2.2.1
54 Rev.Q 3HAC9112-1
2 Specification of Variants and Options2.3.2 Process equipment
2.3.2 Process equipment
Power source
Current/Hose set
Feed kit
Torch service
Option Type Description
1029-13 AristoMig 4000i 400 V including wirefeederOnly together with option 878-2 or 878-3.
1029-14 AristoMig 5000i 400 V including wirefeederOnly together with option 878-2 or 878-3.
Option Type Description
1030-4 7.5 m For external suspension mounting, not included.Only together with option 1029-13 or 1029-14.
1030-5 10 m Internal suspension mounting, hose package attatched to the robot base. Protective hose included. Only together with option 1029-13 or 1029-14.
Option Type Description
1033-2 Marathon Pac Octagon
Liner for 250 kg Marathon Pac. Plastic hood for round Maraton-Pac included.
1033-3 Bobbin A 15 kg bobbin holder on the robot.
Option Type Description
1037-1 ABB TSC ABB Torch Service Center.
1037-2 ABB TC96 ABB Torch cleaner.
1037-5 BullsEye BullsEye stand alone.
3HAC9112-1 Rev.Q 55
2 Specification of Variants and Options2.3.3 AW Safety options
2.3.3 AW Safety options
Working area
Operator panel
AW Safety interface
Lightbeam
Gate switch
Home position switch
Option Type Description
1072-1 One working area
1072-2 Two working areas
Option Type Description
1054-1 Operator panel 1 area
For one working area
1054-2 Operator panel 2 areas
For two working areas.
1054-3 2 x operators panel 2 areas
Two operator panels, one for each working area.
Option Type Description
1058-1 Safety interface SIB, requires options 735-3 and 735-4.
1058-2 Active relay Active relay supervision (open relay).
Option Type Description
1059-1 Lightbeam Qty 1 or 2, one working area requires one PC of ”two level light beams”.Two working areas rerquire two PCs of “two level light beams”.
Option Type Description
1060-1 Gate switch
1060-2 Gate switch/ ext. reset
Option Type Description
1061-1 Home position switch
Home position switch for IRB 1600/2400, one work-ing area.
56 Rev.Q 3HAC9112-1
2 Specification of Variants and Options2.3.4 Documentation
Station indication
Pre-reset unit
Activation unit
Extended EM stop
2.3.4 Documentation
DVD User Documentation
Option Type Description
1062-1 Station indication Station indication for IRB 1600/2400, two working areas.
Option Type Description
1063-1 Pre-reset unit Qty 1 or 2, one working area requires one PC of “Pre-reset”. Two working areas require two PCs of “Pre-reset”.
Option Type Description
1064-1 Activation unit Qty 1 or 2, one requires one PC of “Activation unit”. Two working areas require two PCs of “Activation unit”.
Option Type Description
1065-1 Extended EM stop Required when using external EM-stop push buttons and when ordering a dual arc system (two welding packages).
Option Type Description
808-1 Documentation on DVD
See Product Specification - Robot User Documentation
3HAC9112-1 Rev.Q 57
2 Specification of Variants and Options2.3.4 Documentation
58 Rev.Q 3HAC9112-1
3 Accessories
3 AccessoriesGeneral
There is a range of tools and equipment available, specially designed for the robot.
Basic software and software options for robot and PCFor more information, see Product specification - Controller IRC5 with FlexPendant, and Product specification - Controller software IRC5/RobotWare.
Robot Peripherals• Track Motion
• Motor Units
3HAC9112-1 Rev.Q 59
3 Accessories
60 Rev.Q 3HAC9112-1
Index
Aaccessories, 59Active Brake System, 15active safety system, 15air supply, 47Application interface, 47
connection to, 48AW Safety options, 56
Activation unit, 57AW Safety interface, 56Extended EM stop, 57Gate switch, 56Home position switch, 56Lightbeam, 56Operator panel, 56Pre-reset unit, 57Station indication, 57Working area, 56
Ccalibration, 34, 35Collision detection, 16compact robot arm, 16Connector kit, 48cooling device, 10
Ddesign, 16Documentation, 57
EElectronically Stabilised Path, 16emergency stop, 17enabling device, 17equipment
mounting, 30permitted extra load, 30
extra equipmentconnections, 47
FFloor cables, 52
Manipulator, 52Manipulator, cable length, 52Manipulator, cable length-position switches axis 1,
53Manipulator, connection of Parallel communica-
tion, 52forklift, 44
Hhold-to-run control, 17humidity, 19
Iinstallation, 18Installation kit, 54
Internal Safety Concept, 17inverted robot, 18
Llimitation, 16load, 18, 20
Mmaintenance, 37manipulator colors, 45mechanical interface, 33motion, 38mounting
extra equipment, 30robot, 20
mounting flange, 33moveable, mechanical, main axes, 16
Nnoise level, 10
Ooperating requirements, 19option Absolute Accuracy, 35options, 45
PPassive Safety System, 16payload, 18performance, 42Positioner
Positioner cable 1, 53Positioner cable 2, 53Positioner cable type, 53Return cable, 53Weld return cable, 53
Positioners, 51positioning accuracy, 36Process, 54Process equipment, 55
Current/Hose set, 55Feed kit, 55Power source, 55Sensors, 56Torch service, 55
Process module, 54protection
foundry, 46standard, 46
protection standards, 19
Rrange of movement
working space, 38reduced speed, 17references, 34repeatability, 42
3HAC9112-1 Rev.Q 61
Index
Robot Peripherals, 59robot versions, 10
Ssafeguarded space stop, 17
delayed, 17safety, 14Safety category 3, 17Safety lamp, 49safety lamp, 17Self Tuning Performance, 16Service
ABB Torch cleaner, 55ABB Torch Service Center, 55
service, 37Service Information System, 15service information system, 15signal connections, 47space requirements, 10standards, 14structure, 7suspended robot, 18
Ttemperature, 19Track Motion, 51
type, 51Track motion RTT
Example of ordering, 51Travel length
additional, 51troubleshooting, 37
VVariants, 45variants, 45
Wweight, 10Working range limit
Axis 1, 50axis 2, 50axis 3, 51
working spacerestricting, 16, 18
62 Rev.Q 3HAC9112-1
ABB ABRobotics ProductsS-721 68 VÄSTERÅSSWEDENTelephone: +46 (0) 21 344000Telefax: +46 (0) 21 132592
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