ABB IRB 2400/L Product Manual
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ABB IRB 2400/L Product Manual

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Summary of Contents for ABB IRB 2400/L

  • Page 1 ROBOTICS Product manual IRB 2400...
  • Page 2 Trace back information: Workspace R18-1 version a9 Checked in 2018-03-22 Skribenta version 5.2.025...
  • Page 3 Product manual IRB 2400/L IRB 2400/10 IRB 2400/16 M2000, M2000A, IRC5 Document ID: 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 4 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.

  • Page 5: Table Of Contents

    Electrical connections ..................2.5.1 Connectors on robot ................2.5.2 Robot cabling and connection points ............Start of robot in cold environments ..............Maintenance Introduction ...................... Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 6 Calibration methods ................... Synchronization marks and synchronization position for axes ........Calibration movement directions for all axes ............Updating revolution counters ................Checking the synchronization position ..............Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 7 Standard tools ....................Special tools ....................Lifting equipment and lifting instructions ..............Spare part lists Spare part lists and illustrations ................Circuit diagram Circuit diagrams ....................Index Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    • repair personnel. Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
  • Page 10 This manual contains all safety instructions from the product manuals for the manipulators and the controllers. Additional document references Document name Document ID Application manual - CalibWare Field 5.0 3HAC030421-001 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 11 Revised terminology: robot replaced with manipulator. Content updated in chapter/section: • Corrected spare part number for gasket in Spare parts - upper arm, IRB 2400/L. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 12 Published in release R16.2. The following updates are done in this revision: • Corrections due to updates in terminology. • Location of labels figure added. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 13 General procedures on page 112. • Safety restructured. • Updated spare part number brake release board (was DSQC563, is DSQC1050). • Information about myABB Business Portal added. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 14: How To Read The Product Manual

    Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 15: Product Documentation, M2000/M2000A

    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.

  • Page 16: Product Documentation, Irc5

    Product documentation, IRC5 Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 17 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 18 This page is intentionally left blank...

  • Page 19: Safety

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
  • Page 20 Grippers/end effectors must be designed so that they retain work pieces in the event of a power failure or a disturbance to the controller. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 21 1.1.1 Limitation of liability Continued Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected. CAUTION Ensure that a gripper is prevented from dropping a work piece, if such is used.

  • Page 22: Protective Stop And Emergency Stop

    1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 23: Safety Actions

    1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 24: Emergency Release Of The Robot Axes

    When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 25: Make Sure That The Main Power Has Been Switched Off

    To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 26: Safety Risks

    Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 27 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

  • Page 28: Moving Robots Are Potentially Lethal

    The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 29: First Test Run May Cause Injury Or Damage

    If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 30: Work Inside The Working Range Of The Robot

    Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 31: Enabling Device And Hold-To-Run Functionality

    How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 32: Risks Associated With Live Electric Parts

    The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 33 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 34: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 35: Hot Parts May Cause Burns

    Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 36: Safety Risks Related To Pneumatic/Hydraulic Systems

    Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 37: Brake Testing

    3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 38: Safety Risks During Handling Of Batteries

    Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 39: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    Possible pressure build-up in gearbox Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 40 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 41: Safety Signals And Symbols

    ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 42 Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 43: Safety Symbols On Product Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 44 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 45 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 46 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 47 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 48 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 49: Installation And Commissioning

    If the IRB 2400 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 50: Unpacking

    It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
  • Page 51 The values also never reach their maximum at the same time! WARNING The robot installation is restricted to the mounting options given in following load table(s). Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 52 If resolver/encoder calibration is changed this will influence the absolute accuracy. Maximum tilt 5° Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 53 Manipulator, protection type Standard IP 54 Manipulator, protection type Foundry Plus IP 67 Manipulator, protection type Clean Room IP 54 Manipulator, protection type Wash IP 67 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 54: Working Range

    Pos. Angle axis 2 Angle axis 3 1620 2298 1577 -246 -403 24.5 -1611 -100 -115 1088 -100 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 55 The table below specifies the positions inside the working range, shown in the figure above. Position in figure Position (mm) Angles (º) Axis 2 Axis 3 1139 1246 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 56 2 Installation and commissioning 2.2.2 Working range Continued Position in figure Position (mm) Angles (º) Axis 2 Axis 3 1506 1313 1148 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 57: Risk Of Tipping/Stability

    Do not change the robot position before securing it to the foundation! WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 58: On-Site Installation

    Attach the straps to the special eye bolts on the gearboxes for axes 2 and 3. Lift the robot carefully. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 59: Manually Releasing The Brakes

    The brake will function again as soon as the button is released. xx0600002697 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 60 +24 V on pin B8 • 0 V on pin C10 xx0200000167 Release the brakes with the brake release unit as detailed in the previous procedure. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 61: Orienting And Securing The Robot

    M16 x 50 Quality Quality 8.8 Suitable washer: Thickness: 3 mm Outer diameter: 30 mm Inner diameter: 17 mm Tightening torque: 190 Nm Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 62 Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be remounted without re-adjusting the program. Equipment Art. no. Guide sleeves 2151 0024-169 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 63: Mounting The Robot In Suspended Position

    Turning the robot 1 Use the special tool for inverted mounting, see following figure. xx0200000212 Lifting beam Fork lift Inverted mounting tool 3HAB8961-1 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 64 2.3.4 Mounting the robot in suspended position Continued 2 Seal the eight holes in the bottom plate with plastic plugs, see following figure. xx0200000215 Plastic plugs (x8) Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 65: Loads Fitted To The Robot, Stopping Time And Braking Distances

    The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 66: Signal Lamp (Option)

    The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 67: Setting The System Parameters For A Suspended Or Tilted Robot

    The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 68 B is the mounting angle in radians. Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 69 90° (Wall) 1.570796 -90° (Wall) -1.570796 Note For suspended robots (180°), it is recommended to use Gravity Beta instead of Gravity Alpha. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 70 The system parameters are described in Technical reference manual - System parameters. The system parameters are redefined in the Configuration Editor, in RobotStudio or on the FlexPendant. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 71: Restricting The Working Range

    This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 72: Mechanically Restricting The Working Range Of Axis 1

    The restrictions are made by fitting two extra stops to the robot base and adjusting the system parameter configuration. xx0500002105 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 73 Make a copy of the drill template, enclosed with The template is also shown in the the mechanical stop. figure Drill template on page 77 scale 1:1. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 74 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 75 2 x 4º, which corresponds to the width of the stop pin (at the frame). Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 76 Hidden stiffening ribs and forbidden drilling sector xx0600002647 Drilling not allowed inside this sector! Center lines for the hidden stiffening ribs Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 77 2 Installation and commissioning 2.4.2 Mechanically restricting the working range of axis 1 Continued Drill template xx0200000207 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 78: Mechanically Restricting The Working Range Of Axis 2

    +50° / -40° +20° / -100° +20° / -70° +20° / -40° Required equipment Equipment Art. no. Note Stop, axis 2 3HAC 2624-1 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 79 4.0) (RobotWare 4.0) References on page Technical reference manual - System parameters Standard toolkit The content is defined in the section Standard tools on page 229. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 80: Installation Of Limit Switch, Axis 3

    3, which senses the position via a cam. The system parameter configuration must also be updated. Mounting of eletrical stop Following illustration shows how to fit the electrical stop. xx0200000211 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 81: Electrical Connections

    2.5 Electrical connections 2.5.1 Connectors on robot Connectors on the robot The figure below shows all connections of the robot cabling, including the customer connections. xx0500002043 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 82: Robot Cabling And Connection Points

    Robot cable, power: 7 m 3HAC9038-1 Robot cable, power: 15 m 3HAC9038-2 Robot cable, power: 22 m 3HAC9038-3 Robot cable, power: 30 m 3HAC9038-4 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 83 Position switch cable, axis 1, 15 m 3HAC7997-2 R1.SW Position switch cable, axis 1, 22 m 3HAC7997-3 R1.SW Position switch cable, axis 1, 30 m 3HAC7997-4 R1.SW Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 84: Start Of Robot In Cold Environments

    If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 85: Maintenance

    If the IRB 2400 is connected to power, always make sure that the IRB 2400 is connected to protective earth before starting any maintenance work. For more information see: • Product manual - IRC5 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 86: Maintenance Schedule

    Service Information System, M2000 on page 103. The SIS used in M2004 is further described in the Operating manual - Service Information System. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 87: Maintenance Schedule

    The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced. See the replacement instruction for more details. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 88: Inspection Activities

    Warning sign - Symbol of flash (5 pcs) UL/UR label Instruction plate - Lifting of robot Designation sign Information sign - AbsAcc Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 89 Check all labels. See the figure in Location of information labels on page Replace any missing or damaged labels. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 90: Inspecting Signal Lamp (Option)

    Use this procedure to inspect the function of the signal lamp. Note If the signal lamp is damaged, it shall be replaced! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 91 Cut the paint or surface on the robot be- fore replacing parts on page 117. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 92: Changing Activities

    Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.

  • Page 93: Oil Change, Gearbox Axes 5-6 (Wrist Unit)

    Standard toolkit The content is defined in the section Standard tools on page 229. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 94 Shown in the figure Location of oil plugs, axes 5-6 (IRB 2400L/5) on page Turn axis 5 -30° if necessary to drain all oil. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 95 The procedure below details how to refill oil to the wrist unit. Action Note Run the upper arm to a horizontal position and turn axis 4 to the calibration position. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 96 5) until the oil reaches up to the hole located on the side of the wrist. Note If the robot is mounted in suspension, the wrist should be turned 180°. Refit the oil plugs to the wrist. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 97: Replacement Of Smb Battery

    Can only be used with SMB unit 3HAC046277-001 containing SMB board 3HAC044168-001. Gasket, cover 3HAC3200-1 Always replace with a new one! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 98 Always replace a removed gasket with a new gasket. a new! Spare part no. is specified in Required equipment on page Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 99 3 Maintenance 3.4.3 Replacement of SMB battery Continued Action Note Update the revolution counters! Detailed in the section Updating revolu- tion counters on page 210. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 100: Cleaning Activities

    Never point the water jet at connectors, joints, sealings, or gaskets. • Do not use compressed air to clean the robot. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 101 3 Maintenance 3.5.1 Cleaning the IRB 2400 Continued • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. • Do not remove any covers or other protective devices before cleaning the robot.
  • Page 102 3.5.1 Cleaning the IRB 2400 Continued Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...

  • Page 103: Service Information System, M2000

    110. parameters are to be entered from an extern- al PC, a set of software tools are available to build such an application. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 104: Description Of Service Information System (Sis)

    Setting the SIS parameters on page 108. Remaining time Remaining time to next scheduled service date. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 105 Service interval exceeded When the service time has been exceeded for the selection made, an error message (Service interval exceeded!) is displayed. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 106 No data available When no data is available for the selection made, a message (No data available!) is displayed when trying to display the data. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 107: Sis System Parameters

    The values can be defined by the operating organization as knowledge of the robot's working conditions are accumulated. Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. Operation time limit (service level) The number of operation hours selected as service interval.

  • Page 108: Setting The Sis Parameters

    Select the required paramet- Available parameters are described in section SIS system ers by stepping up and parameters on page 107. down through the parameter list. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 109: Reading The Sis Output Logs

    How to set the value determining when the mes- gearbox x! sage is to be shown, is detailed in section Setting the SIS parameters on page 108. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 110: Exporting The Sis Data

    Operation time of gearbox axis 3 sisL10h_6 hours Gearbox time Estimated life of gearbox axis 6 sisL10h_Time_6 hours Gearbox time Operation time of gearbox axis 6 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 111: Repair

    If the IRB 2400 is connected to power, always make sure that the IRB 2400 is connected to earth before starting any repair work. For more information see: • Product manual - IRC5 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 112: General Procedures

    Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 113: Mounting Instructions For Bearings

    Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 114 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 115: Mounting Instructions For Seals

    Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 116 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.

  • Page 117: Cut The Paint Or Surface On The Robot Before Replacing Parts

    Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 118 Clean Room. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 119: The Brake Release Buttons May Be Jammed After Service Work

    If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 120: Complete Robot

    Connectors at motor 3; R3.MP3, R3.FB3,R3.LS1 and R3.LS2 Connectors at motor 1; R3.MP1, R3.FB1 Upper bracket Cable guide in the middle of the frame Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 121 Axis 5: +90° • Axis 6: no significance DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 122 Remove the cover of the motors 1-3. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 123 3, with the five attachment screws. Refit the upper bracket securing the cables to the arm house, using the two attachment screws. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 124 Connect all the earth cables on the R1.M1-3 cable to the back of the cover. xx0200000403 Connect the connectors R1.MP1-3 and R2.BU1-3 inside the base. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 125 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 126: Replacement Of Cable Harness, Axes 4-6

    Connectors at motor 6, R3.MP6 and R3.FB6 Connectors R3.H1 and R3.H2 (5 kg option) Connectors R3.H1 and R3.H2 (15 kg option) Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 127 Axis 2: 0 ° • Axis 3: 0 ° • Axis 4: 0 ° • Axis 5: +90 ° • Axis 6: no significance Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 128 Note! Different robot versions are fitted with different plate versions. Make sure the correct one is used to avoid cable failure. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 129 The procedure below details how to refit the cable harness, axes 4-6. Action Note/Illustration DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the ro- bot! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 130 Note! Always use a new gasket! Art. no. is on motor 4-6 using the nine torx screws specified in Required equipment on page 127. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 131 C - R3.MP4 D - R3.FB5 E - R3.FB6 F - R3.FB4 xx0200000406 xx0300000063 xx0300000062 Fit the back cover of the motors 4-6. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 132 Run all the earth cables on the R1.M4-6 cable to the back of the cover. xx0200000403 Connect connectors R1.MP4-6 and R2.BU4-6. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 133 These are further detailed in the section First test run may cause injury or dam- age on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 134: Upper Arm

    The wrist is defined as the axis 5 and 6 of the robot. This is shown in pos (A) in the figure below. xx0300000103 Wrist Upper arm Lower arm Frame Base Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 135 See refer- references to the tools re- ences to these procedures quired. in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 136 It is a replacement unit of complex design and should not normally be serviced on-site. Instead it should be sent to ABB for service etc. ABB recommends its customers to carry out only the following servicing and repair work on the wrist.
  • Page 137 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 138: Replacement Of Wrist Irb 2400L

    The wrist is defined as the axis 5 and 6 of the robot and shown in pos (A) in the figure below. xx0200000409 Wrist Upper arm Lower arm Frame Base Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 139 It is a replacement unit of complex design and should not normally be serviced on-site. Instead it should be sent to ABB for service etc. ABB recommends its customers to carry out only the following servicing and repair work on the wrist.
  • Page 140 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 141: Replacement Of Complete Upper Arm

    The complete upper arm includes the wrist unit. xx0200000409 Wrist axis 5-6 Upper arm axis 3-4 Lower arm axis 2 Frame axis 1 Base Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 142 KM nuts Attachment screw Sealing (insert a strap under the sealing to let the air go out when fitting the cover) Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 143 142. Raise the upper arm into the mounting position. Fit shaft spindles (both sides). Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 144 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 145: Lower Arm

    A more detailed view of the component and its position may be found in chapter Spare part lists on page 233. xx0200000409 Wrist Upper arm Lower arm Frame Base Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 146 CAUTION The robot lower arm weighs 27 kg without any additional equipment fitted. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 147 Remove the attachment screws and the spring tension plate. xx0200000440 Attachment screws Remove the lower arm. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 148 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 149: Replacement Of Tie Rod

    A more detailed view of the component and its position may be found in chapter Spare part lists on page 233. xx0200000444 Tie rod Parallel arm Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 150 3HAB6331-1 Used to fit the tie rod. Standard toolkit The content is defined in the section Standard tools on page 229. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 151 The procedure below details how to refit the tie rod to the robot. Action Note DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 152 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 153: Frame And Base

    Note that the robot is shown with the SMB cover already removed! xx1300000289 SMB battery cable SMB battery RMU (3-pole battery contact) SMB unit RMU 101 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 154 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 117. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 155 4.6.1 Replacement of SMB unit Continued SMB unit, layout xx0600002645 Connector R2.SMB4-6 Connector R2.SMB1-3 Connector R2.SMB1-2 (external axis) Connector R2.SMB Connector R2.G (battery unit) Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 156 The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 34 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 157 Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards. xx1700000993 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 158 Art. no. is specified in Required equip- ment on page 154. Update the revolution counters! Detailed in the section Updating revolu- tion counters on page 210. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 159: Replacement Of Brake Release Unit

    The brake release unit is located behind the base cover at the robot base, as shown below. xx1700001192 Base cover Push-button guard Brake release unit (located inside the base) Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 160 Brake release unit with harness 3HAC065018-001 DSQC1050 and bracket Standard toolkit The content is defined in the sec- tion Standard tools on page 229. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 161 Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 162 119! Refit the cover to the rear of the base. Refit the push button guard to the base cover. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 163 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 164: Replacement Of Parallel Arm

    Parallel arm Required equipment Equipment Spare part no. Art. no. Note Groove ball bearing 3HAB3643-12 Sealing ring 3HAB5515-1 Bearing grease 3HAB3537-1 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 165 Detailed in section Removal, tie rod on page 151. Remove the parallel arm by removing its eight at- tachment screws and washers. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 166 Fit one of the two V-rings to the parallel arm. Shown in the figure Assembly, par- allel arm on page 166. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 167 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 168: Motors

    Spare part lists on page 233. xx0200000465 Cover Connection box Attachment screws and washers, motor (4 pcs) Motor axis 1 Correct orientation of holes Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 169 The procedure below details how to remove the motor, axis 1. Action Note/Illustration DANGER Turn off all electric power, hydraulic and pneu- matic pressure supplies to the robot! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 170 Fit the new o-ring. Always fit a new one, see article number in Required equipment on page 169. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 171 Location of mo- ment screws and plain washers. tor, axis 1 on page 168. Make sure the gasket is fitted properly! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 172 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 173: Replacement Of Motor, Axis 2

    Cover Connection box Gasket Motor, axis 2 Attachment screws, motor (4 pcs) O-ring Correct orientation of holes on top of motor Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 174 Remove the cover of the connection box. Shown in the figure Location of mo- tor, axis 2 on page 173. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 175 Location of mo- of the motor. tor, axis 2 on page 173. Remove the motor by gently lifting it straight out. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 176 A Measuring tool Set the gear play to 0.02 mm, which corresponds to a reading on the dial indicator of 0.13 mm. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 177 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 178: Replacement Of Motor, Axis 3

    Cover Connection box Gasket Motor, axis 2 Attachment screws, motor (4 pcs) O-ring Correct orientation of holes on top of motor Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 179 Remove the cover of the connection box. Shown in the figure Location of mo- tor, axis 3 on page 178. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 180 Location of mo- washers of the motor. tor, axis 3 on page 178. Remove the motor by gently lifting it straight out. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 181 A Measuring tool Set the gear play to 0.02 mm, which corres- ponds to a reading on the dial indicator of 0.13 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 182 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 183: Replacement Of Motors, Axes 4-6, Irb 2400L

    Motor unit axes 5-6 3HAC11865-1 (Elmo) Motor unit axes 5-6 3HAC021741-001 (Yaskawa) O-ring 21522011-414 Locking liquid 3HAB7116-1 Loctite 243 Bearing grease 3HAB3537-1 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 184 Remove the cover of the connection box. Shown in the figure Location of motors axes 4-6 on page 183. Loosen connectors R3.MP5-6 and R3.FB5-6. xx0300000063 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 185 Remove the motor by unscrewing its attachment screws and plain washers. Remove the motor by gently lifting it straight out (horizontal movement). Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 186 “chewing”. Do not use force! Tighten the motor attachment screws and 4.1 Nm secure them with locking fluid. Loctite 243 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 187 In order to release the brakes, connect the 24 Connector to connector R3.MP5: VDC power supply to the motor. • + : pin 7 • -: pin 8 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 188 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 189 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 190: Replacement Of Motors, Axes 4-6, Irb 2400/10/16

    IRB 2400/16 (Elmo) Motor unit axis 5 3HAC021722-001 Color: ABB Orange IRB 2400/10/16 (Yaskawa) 3HAC021722-003 Color: Graphite White IRB 2400/10/16 (Yaskawa) Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 191 Drain the oil from the axis 4 gearbox. Remove the cover of the connection box. Shown in the figure Location of motors axis 4-6 on page 190. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 192 Required equipment on page 190. Lubricate the gear with bearing grease. Art. no. is specified in Required equipment on page 190. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 193 General calibration information is included in the section Calibration information on page 205. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 194 Tightening torque: 4.1 Nm. them with locking fluid. Loctite 243 Reconnect the cabling. Detailed in section Refitting, cable harness, axes 4-6 on page 129. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 195 Find the smallest play for axis 6 within this area. Use swift movements to avoid noticing the magnetic field, which makes the gears stick together Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 196 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 197: Gearboxes

    See refer- references to the tools re- ences to these procedures quired. in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 198 The procedure below details how to refit the gearbox, axis 1-3. Action Note DANGER Turn off all electric power, hydraulic and pneu- matic pressure supplies to the robot! Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 199 Make sure all safety requirements are met when performing the first test run. These are further described in the section First test run may cause injury or damage on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 200: Replacement Of Drive Shaft Unit, Irb 2400L

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 117. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 201 Removal, drive shaft unit The procedure below details how to remove the drive shaft unit from the robot upper arm. NOTE! ABB recommends its customers to carry out only the following servicing and repair work on the drive shaft unit. Action...
  • Page 202 Refitting, drive shaft unit The procedure below details how to remove the drive shaft unit from the robot upper arm. NOTE! ABB recommends its customers to carry out only the following servicing and repair work on the drive shaft unit. Action...
  • Page 203 These are further detailed in the section First test run may cause injury or dam- age on page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 204 This page is intentionally left blank...

  • Page 205: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

  • Page 206: Calibration Methods

    Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P ©...
  • Page 207 Levelmeter calibration - alternative method Levelmeter calibration is referred to as the alternative method for calibration of ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.

  • Page 208: Synchronization Marks And Synchronization Position For Axes

    This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 2400 The illustration below shows the calibration marks on all axes of the robot. en0200000273 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 209: Calibration Movement Directions For All Axes

    Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 210: Updating Revolution Counters

    Make sure the axes are positioned according to the correct calibration values, not only according to the synchronization marks. The correct values are found on a Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 211 The Calibration window appears. If there is more than one unit connected to the manipulator, they will be listed in the window. xx0100000201 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 212 Check the synchronization position very carefully after each update. How to perform the check is detailed in section Checking the synchron- ization position on page 215. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 213 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 214 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 215. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 215: Checking The Synchronization Position

    If they do not, update the revolu- synchronization position for axes on tion counters. page 208 Updating revolution counters on page 210. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 216: Product Manual - Irb

    If they do not, up- ization position for axes on page 208 date the revolution counters. Updating revolution counters on page 210. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 217: Decommissioning

    Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 218 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 219: Scrapping Of Robot

    • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
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  • Page 221: Reference Information

    7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 222: Applicable Standards

    Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 223 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 224: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 225: Screw Joints

    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.
  • Page 226 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 227 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 228: Weight Specifications

    All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

  • Page 229: Standard Tools

    Socket head cap no: 6, socket 1/2" bit L 20 mm Socket head cap no: 8, socket 1/2" bit L 20 mm Small cutting plier T-handle with ball head Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 230: Special Tools

    The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method. Description Art. no. Note Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 231: Lifting Equipment And Lifting Instructions

    This implies that the instructions delivered with the lifting equipment should be stored for later reference. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 232 This page is intentionally left blank...

  • Page 233: Spare Part Lists

    Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 234 This page is intentionally left blank...

  • Page 235: Circuit Diagram

    Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 236 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.

  • Page 237: Index

    19 external safety devices, 27 interval connectors maintenance, 87 on robot, figure, 81 copper labels disposal, 217 robot, 43 customer connections, 81 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 238 43 disposal, 217 test run, 29 position switch working range, 30 axis 3, 80 safety equipment positive directions, axes, 209 mechanical stop axis 1, 72 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 239 2, 78 system parameter restricting axis 3, 80 Gravity Alpha, 68 wrist, replacing, 134, 138 Gravity Beta, 67 zero position temperatures checking, 215 operation, 53 Product manual - IRB 2400 3HAC022031-001 Revision: P © Copyright 2004-2018 ABB. All rights reserved.
  • Page 242 Robotics and Motion No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2004-2018 ABB. All rights reserved.

This manual is also suitable for:

Irb 2400 seriesIrb 2400/10Irb 2400/16Irb 2400

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