Page 1 ROBOTICS Product manual IRB 1010...
Page 2 Trace back information: Workspace 22D version a9 Checked in 2022-12-16 Skribenta version 5.5.019...
Page 4 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, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Installing movable mechanical stops on axis 1 ..........Electrical connection ..................3.5.1 Robot cabling and connection points ............3.5.2 Customer connections ................Start of robot in cold environments ..............Maintenance Introduction ...................... Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 6 Verifying the calibration ..................Checking the synchronization position ..............Troubleshooting Introduction to troubleshooting ................Oil and grease stains on motors and gearboxes ............Mechanical noise or dissonance ................Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 7 Unit conversion ....................Screw joints ....................Weight specifications ..................Standard toolkit ....................Special tools ....................10 Spare parts 10.1 Spare part lists and illustrations ................Index Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
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Page 9: Overview Of This Manual
Product manual scope The manual covers all variants and designs of the IRB 1010. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 Overview of this manual Continued References Documentation referred to in the manual, is listed in the table below. Document name Document ID Product manual, spare parts - IRB 1010 3HAC081965-001 Product specification - IRB 1010 3HAC081966-001 Circuit diagram - IRB 1010 3HAC080051-003...
Page 11: Product Documentation
Product documentation 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 12 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 13: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several product models, can be illustrated with illustrations that show a different product model than the one that is described in the current manual. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
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Page 15: Safety
The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.
Page 16: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 17: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 18 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 19: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 20 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 21 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 22 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 23 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 24 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 25: Robot Stopping Functions
The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - OmniCore E10 Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 26: Safety During Installation And Commissioning
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 27 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 28: Safety During Operation
Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 30 Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 31 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 32: 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 33: Brake Testing
For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 34: Safety During Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 35: Safety During Decommissioning
Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
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Page 37: Manipulator Description
2.1 About IRB 1010 Introduction The IRB 1010 is one of ABB Robotics latest generation of 6-axis robot, with a payload of 1.5 kg, designed specifically for manufacturing industries that use flexible robot-based automation, e.g. 3C industry. The robot has an open structure that is especially adapted for flexible use, and can communicate extensively with external systems.
Page 38: Technical Data
Force in any direction in the XY plane Force in the Z plane Bending torque in any direction in the XY plane Bending torque in the Z plane Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 39 If resolver/encoder calibration is changed this will influence the absolute accuracy. Maximum tilt 5° Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 40 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP40 According to IEC 60529. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 41 2 Manipulator description 2.2 Technical data Continued The IRB 1010 has IP40 as default. And the IRB 1010 fulfill clean room class 5 standard according to DIN EN ISO14644-1, -14. Environmental information The product complies with IEC 63000. Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances.
Page 42: Dimensions
2 Manipulator description 2.3 Dimensions 2.3 Dimensions Main dimensions of IRB 1010-1.5/0.370 xx2200000188 Description Turning radius: R67 Turning radius: R83 Turning radius: R113 Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 43: Working Range
-90° pos5 +270.5 +225.6 +125° -180° pos6 -226.6 +59.2 -75° -180° pos7 -11.0 +316.1 -75° +50° pos8 -357.4 +285.8 -75° -90° Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 44 ±360° Default value. ±242° Maximum revolution value. The default working range for axis 6 can be extended by changing parameter values in the soft- ware. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 45: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
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Page 47: Installation And Commissioning
Safety on page 15 before performing any installation work. Note Always connect the IRB 1010 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: •...
Page 48: 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 49: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx2200000181 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 50: On-Site Installation
This section describes how to lift the robot and move it by one person. Grasping location When moving the IRB 1010, stands behinds the robot (base rear side) and holds the lower part of the arm. The following figure illustrates the recommended grasping location of the robot.
Page 51 Be careful so that the robot does not bump into something while lifting and transporting. It could damage the robot. Secure the robot on a workbench according to section Orienting and securing the robot on page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 52: Lifting And Rotating A Suspended Mounted Robot
3.3.1.2 Lifting and rotating a suspended mounted robot 3.3.1.2 Lifting and rotating a suspended mounted robot Introduction How to lift and turn the robot to a suspended position: Contact ABB for more information. Product manual - IRB 1010 3HAC081964-001 Revision: B...
Page 53: Orienting And Securing The Robot
Washers: 8.4 x 16 x 1.6 Tighten the bolts in a crosswise pattern to ensure Tightening torque: 20 Nm±2 Nm that the base is not distorted. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 54 3.3.2 Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. + 0,012 6 H7 SECTION J-J xx2200000191 Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 55: Manually Releasing The Brakes
Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 56 If they are mixed up, damage can be caused to internal electrical components. xx1800002443 Use the brake releasing button as described in Releasing the brakes on page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 57: Setting The System Parameters For An Inverted Or A 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 58 B is the mounting angle in radians. Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Inverted mounting 180° 3.141593 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 59 The value of the system parameters that define the mounting angle must be redefined when changing the mounting angle of the robot. The parameters belong to the type Robot, in the topic Motion. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 60 3.3.4 Setting the system parameters for an inverted or a tilted robot Continued The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 61: 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. See Product specification - Robot stopping distances according to ISO 10218-1. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 62: Fitting Equipment On The Robot (Robot Dimensions)
3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) 3.3.6 Fitting equipment on the robot (robot dimensions) Robot dimensions The figure shows the dimension of the IRB 1010-1.5/0.370. xx2200000188 Description Turning radius: R67 Turning radius: R83 Turning radius: R113 Attachment holes and dimensions Extra loads can be mounted on robot.
Page 63 Tool flange standard + 0,021 20 H7 I - I + 0,012 5 H7 0.05 4xM5 Drill dp 9.5 31,5 DETAIL G xx2200000190 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 64 When fitting tools on the tool flange, only use screws with quality 12.9. For other equipment use suitable screws and tightening torque for your application. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 65: Installation Of Signal Lamp (Option)
The lamp is now ready for use and is lit 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. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 66 3.3.7 Installation of signal lamp (option) Continued Further information about how to set up I/O system may be found in Technical reference manual - System parameters. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 67: Working Range Alterations
Part of the casting or fixed on the casting and can not /should not be removed. Can be installed in one or more than one position, to ensure a reduced working range, or be removed to allow extended working range. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 68: Mechanically Restricting The Working Range
Axis 2, axis 4 and axis 5 have castings as mechanical stops to restrict working range, which could not be replaced. Axis 1 xx2200000198 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 69 3 Installation and commissioning 3.4.2 Mechanically restricting the working range Continued Axis 2 xx2200000199 Axis 3 xx2200000200 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 70 3 Installation and commissioning 3.4.2 Mechanically restricting the working range Continued Axis 4 xx2200000201 Axis 5 xx2200000202 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 71 Installation of mechanical stop, axis 1 and axis 3 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 72 Discard the old stops and refit with new ones. Axis1 Mechanical stop, screw: 9ADA186- Mechanical stop, washer: 9ADA762-6 Axis 3 Mechanical stop, screw: 9ADA186- Secure the mechanical stops. Tightening torque: 5 Nm Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 73: Installing Movable Mechanical Stops On Axis 1
Refer to the following hole dimension on swing bottom to prepare the stops. 11xM3 xx2200001082 Note Additional mechanical stops are not delivered with the robot. Contact ABB for more information. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 74: Electrical Connection
Robot cable, signals Transfers resolver data from R1.SMB and power supply to the serial measurement board. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 75 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 77: Customer Connections
Description Art. no. Connector kits CP/CS M12 CPCS Male straight connect- 3HAC066098-001 or kits M12 CPCS Male angled connector 3HAC066099-001 kits Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 78 Always remember to refit the protection covers after removing them. xx2200000195 Air hose connector protection covers CP/CS connector protection covers SMB connector protection cover Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 79: 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
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Page 81: Maintenance
Note If the IRB 1010 is connected to power, always make sure that the IRB 1010 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.
Page 82: Maintenance Schedule And Expected Component Life
4.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 1010: • Calendar time: specified in months regardless of whether the system is running or not.
Page 83: Maintenance Schedule
Expected component life on page 85 Maintenance schedule Maintenance activities Reference Cleaning the robot Cleaning the IRB 1010 on page 86 Check for abnormal wear or Inspecting the robot contamination. Inspecting the information labels Inspecting the information labels...
Page 84 4 Maintenance 4.2.2 Maintenance schedule Continued vi Not needed separately if already included in the application. vii Recommended test interval is within the range 8-48 hours. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 85: Expected Component Life
Examples of "extreme usage" in regard to movement: press tending, very severe palletizing applications, major use of axis 1 movement and major use of bending backwards of axis 3. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 86: Cleaning Activities
4.3.1 Cleaning the IRB 1010 General To secure high uptime it is important that the IRB 1010 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the IRB 1010.
Page 87 Remove waste material, such as sand, dust and chips, if it prevents cable movement. • Clean the cables if they have a crusty surface, for example from dry release agents. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 88: Inspection Activities
These figures show the location of the information labels to be inspected. The symbols are described in section Safety symbols on manipulator labels on page Calibration label label xx2200000197 ABB logo Robot model Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 89 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare parts on page 327. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 90: Inspecting The Robot Cabling
Look for abrasions, cuts or crush damage. Replace the cabling if wear or damage is detected. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 91: Inspecting Timing Belts
Use a sonic tension meter to measure the Timing belt tension on page timing belt tension. If the belt has no tension, adjust it! Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 92: Inspecting Mechanical Stops
4.4.4 Inspecting mechanical stops Location of mechanical stops Note Only axis-1 and axis-3 are visible for inspection and available for replacement. Axis 1 xx2200000198 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 93 Axis 3 xx2200000200 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 94 • bent • loose • damaged. Note The expected life of gearboxes can be re- duced as a result of collisions with the mechanical stop. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 95: Lubricating Activities
• electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 96 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have con- tacting area with the cable package. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 97: Replacing/Changing Activities
The battery pack is located as shown in the figure. xx2200000019 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 98 Disconnecting the SMB connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 99 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 101 Refit the SMB cover to the base. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.2 Nm xx2200000012 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 102 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 103: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 1010, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 104: General Procedures
Do not try to grind or polish the shaft surface to get rid of the defect. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 105 Mount the sealing correctly with a mounting tool. Never hammer directly on the sealing as this may result in leakage. xx2000000072 A Gap Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 106 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 107: 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 108: Cable Harness
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 109 M3x10 12.9 Lafre 2C2B/FC6.9+PrO-COat111 Flange socket head screw 3HAB3412-312 M3x12 12.9 Lafre 2C2B/FC6.9+PrO-COat111 Flange socket head screw 3HAB3412-316 M3x16 12.9 Lafre 2C2B/FC6.9+PrO-COat111 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 110 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 111 Removing the covers Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 112 • R2.C1 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2200000032 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 113 Pulling out the cable package from axis 5 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 114 The bracket cannot be removed completely until the cablings are removed from the plate. xx2200000038 Cut the cable strap. xx2200000039 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 115 Make sure axes are well supported before loosening timing belts. Loosen the screws and move the motor slightly to slacken the timing belt. xx2200000042 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 116 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2200000040 Remove the screws and washers. xx2200000044 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 117 R1.MP on page DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 118 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Cut the cable straps. xx2200000050 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 119 Remove the axis-4 cable bracket to separate the cable from the housing. xx2200000052 Remove the axis-4 cable bracket from the cable. xx2200000558 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 120 Removing the axis-3 timing belt Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 121 Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing motors. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 122 Wrap the connectors with the masking tape. Remove the axis-3 cable protector. xx2200000060 xx2200000061 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 123 Removing the axis-2 drive unit Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 124 Remove the screws (12 pcs) securing the axis-2 drive unit to the axis-1 assembly unit. CAUTION Do not remove the innermost screws (16 pcs). xx2200000066 xx2200000068 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 125 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the axis-2 cable protector. xx2200000069 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 126 Removing the base interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 127 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 128 Disconnecting the axis-1 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 129 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 130 Separating the cable package from the axis-1 assembly unit Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 131 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 132 Refit the axis-1 cable protector. Cable protector, axis 1: 3HAC078560-001 Screw: M2.5x6 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 0.4 Nm xx2200000084 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 133 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2200000088 Right view xx2200000089 Left view xx2200000559 Back view xx2200000090 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 134 Check the brake release button. Brake release button: 3HAC068448-001 Replace if damaged. Brake release button assembly tool, included in the special toolkit 3HAC071022-001 xx2200000091 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 135 COat111, 3HAB3412-310(12 pcs) Tightening torque: 1.5 Nm xx2200000080 Insert the axis-1 drive unit connectors through the hole to the robot rear. xx2200000081 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 136 Reconnect the connector R1.BR. Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2200000078 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 137 3HAC071022-001 xx2200000093 Refit the main power connector R1.MP. Screw: M3x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.6 Nm xx2200000076 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 138 If the cables are routed and secured incorrectly the cables can be damaged. Apply grease to the cable package, cover all moving area of the package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 139 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 140 • the screw holes (marked on the red circle) on the drive unit are through-holes. xx2200000543 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 141 Refit the drive unit to the axis 3-4 assembly unit. Flange socket head screw, M3x12 12.9 Lafre 2C2B/FC6.9+PrO- COat111, 3HAB3412-312 (11 pcs) Tightening toroque: 1.5 Nm xx2200000065 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 142 R1.MP according to the section Supplying power to connector R1.MP on page Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 143 Securing the cable package in axis 3 Action Note Route the cable package through the axis 3-4 as- sembly unit. xx2200000097 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 144 Motor orientation: orient the motor 3-4 assembly unit. according to the figure below, in regard to the encircled motor con- nector. xx2200000098 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 145 Do not insert the entire screw to the hole. The screw shall be installed with proper force to avoid shaft rotation. xx2200000544 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 146 Remove the adjustment screw from the motor. Note Pay attention to the screw turning direction. Incor- rect direction may weaken the brake capacity of the motor. xx2200000544 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 147 Refit the axis-4 cable bracket to the cable. Cable bracket, axis 4: 3HAC076867-001 Screw: M2.5x4 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.6 Nm xx2200000558 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 148 2C2B/FC6.9 (3 pcs) Tightening torque: 0.4 Nm If required, disconnect the axis-4 connectors be- fore the refitting. This facilitates the cable routing. xx2200000051 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 149 Refit the wrist unit. Flange socket head screw, M3x16 12.9 Lafre 2C2B/FC6.9+PrO- COat111, 3HAB3412-316 (8 pcs) Tightening torque: 1.2 Nm xx2200000047 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 150 Reconnect the connectors. • See the number markings on the connectors for help to find the corresponding connector. xx2200000538 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 151 R1.MP according to the section Supplying power to connector R1.MP on page xx2200000120 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 152 13.7±1 N (for reference only) tial referenced force. Initial referenced force for new belt: 19.6±1 N xx2200000548 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 153 R1.MP on page Reconnect the connectors. • See the number markings on the connectors for help to find the corresponding connector. xx2200000040 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 154 3HAC076870-001 Screw: M2.5x6 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.3 Nm xx2200000036 Arrange the cable package in axis 6. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 155 Refitting the process hub Action Note For robots with air hoses Reconnect the air hoses. xx2200000031 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 156 Grease: 3HAC029132-001 moving area of the package. Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 157 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 158: Replacing The Smb Unit
The SMB unit is located as shown in the figure. xx2200000002 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 159 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 160 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 161 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Disconnect the battery cable. xx2200000014 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 162 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Check the SMB cable. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 163 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 164 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 165 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 166: Base And Arm System
The base is located as shown in the figure. xx2200000003 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 167 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 168 Disconnecting the SMB connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 169 The interface plate can not be re- moved completely until the connectors are discon- nected, as shown in following steps. xx2200000074 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 170 ESD on page Cut the cable straps. For robots with air hoses Disconnect the air hoses. xx2200000073 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 171 Disconnecting the break release connector Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 172 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The IRB 1010 robot weighs 13.5 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation.
Page 173 Check the brake release button. Brake release button: 3HAC068448-001 Replace if damaged. Brake release button assembly tool, included in the special toolkit 3HAC071022-001 xx2200000091 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 174 COat111, 3HAB3412-310(12 pcs) Tightening torque: 1.5 Nm xx2200000080 Insert the axis-1 drive unit connectors through the hole to the robot rear. xx2200000081 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 175 Securing the robot to the foundation Action Note CAUTION The IRB 1010 robot weighs 13.5 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M8x30 (robot foundation with the attachment screws and installation directly on foundation), washers.
Page 176 3HAC071022-001 xx2200000093 Refit the main power connector R1.MP. Screw: M3x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.6 Nm xx2200000076 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 177 If the cables are routed and secured incorrectly the cables can be damaged. Apply grease to the cable package, cover all moving area of the package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 178 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 179 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 180: Replacing The Axis-1 Assembly Unit
The axis-1 assembly unit is located as shown in the figure. xx2200000004 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 181 Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply Used to release the motor brakes. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 182 If no previous reference values exist, and 4600. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 183 Place the axis-2 sealing assembly tool to the left Axis-2 radial sealing assembly tool: side of the assembly unit. 3HAC082535-001 xx2200000107 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 184 Wipe clean after replacement if any redundant grease. xx2200000596 Grease Main lip Dust lip Fit the new sealing into the assembly unit. xx2200000109 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 185 Check the radial sealing on the left side of the axis-1 assembly unit. Replace if damaged, repeat steps to 10. xx2200000113 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 186 See detailed procedure in Placing the axis 3-4 assembly unit on page 207. Refit the cable package See detailed procedure in Refitting the cable package on page 132. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 187: Replacing The Axis 3-4 Assembly Unit
The axis 3-4 assembly unit is located as shown in the figure. xx2200000005 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 188 Required consumables and wear parts Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Grease 3HAC038379-001 Harmonic Grease Flexolub-1A Used to lubricate the seals. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 189 • Axis 2: 0° • Axis 3: 0° • Axis 4: +130° • Axis 5: -90° • Axis6: No significance xx2200000175 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 190 CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connect- ors are removed. xx2200000030 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 191 The MP6 connector is fitted in particular position. Handle with cautions to not get it stuck. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 192 Do not mix the screws. xx2200000036 Pull out the cable package in the direction as shown in the figure. xx2200000037 Slip out the cable protector. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 193 Disconnect the pressure relief pipe connector. xx2200000041 Pull out the pressure relief pipe carefully from the other side of the wrist unit. xx2200000537 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 194 Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing motors. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 195 Disconnect the connector. • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2200000538 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 196 R1.MP according to the section Supplying power to connector R1.MP on page Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 197 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 198 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Cut the cable straps. xx2200000054 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 199 Loosen the screws and move the motor slightly to slacken the timing belt. xx2200000056 Remove the timing belt from its groove on the motor. xx2200000057 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 200 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 201 R1.MP on page DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 203 Be aware of the connector that is still connected! The drive unit cannot be removed completely until the connector is disconnected. xx2200000067 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 204 Remove the axis-2 sleeve. Use two M3x12 screws to help press out the sleeve. xx2200000070 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 205 Make sure that screw holes and openings on the assembly tool are aligned with those on the as- sembly unit. xx2200000115 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 206 Screw the screws, little by little and evenly, to press the sealing into place. Remove the assembly tool. Check that the sealing is undamaged and properly fitted. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 207 Note the cable routing direction, that is, out from the right side of the robot (the side where the axis- 2 sleeve will be fixed). xx2200000095 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 208 Reconnect the connectors. • See the number markings on the connectors for help to find the corresponding connector. xx2200000064 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 209 Access and reconnect the connector from the swing top. • See the number markings on the connectors for help to find the corresponding connector. xx2200000541 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 210 Supplying power to connector R1.MP on page Check the cooling pad. Cooling pad for axis-2 motor: 3HAC071021-001 Replace if damaged. xx2200000122 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 211 Securing the cable package in axis 3 Action Note Route the cable package through the axis 3-4 as- sembly unit. xx2200000097 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 212 Motor orientation: orient the motor 3-4 assembly unit. according to the figure below, in regard to the encircled motor con- nector. xx2200000098 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 213 Do not insert the entire screw to the hole. The screw shall be installed with proper force to avoid shaft rotation. xx2200000544 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 214 Remove the adjustment screw from the motor. Note Pay attention to the screw turning direction. Incor- rect direction may weaken the brake capacity of the motor. xx2200000544 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 215 Refit the axis-4 cable bracket to the cable. Cable bracket, axis 4: 3HAC076867-001 Screw: M2.5x4 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.6 Nm xx2200000558 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 216 2C2B/FC6.9 (3 pcs) Tightening torque: 0.4 Nm If required, disconnect the axis-4 connectors be- fore the refitting. This facilitates the cable routing. xx2200000051 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 217 Refit the wrist unit. Flange socket head screw, M3x16 12.9 Lafre 2C2B/FC6.9+PrO- COat111, 3HAB3412-316 (8 pcs) Tightening torque: 1.2 Nm xx2200000047 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 218 Reconnect the connectors. • See the number markings on the connectors for help to find the corresponding connector. xx2200000538 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 219 R1.MP according to the section Supplying power to connector R1.MP on page xx2200000120 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 220 13.7±1 N (for reference only) tial referenced force. Initial referenced force for new belt: 19.6±1 N xx2200000548 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 221 R1.MP on page Reconnect the connectors. • See the number markings on the connectors for help to find the corresponding connector. xx2200000040 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 222 3HAC076870-001 Screw: M2.5x6 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.3 Nm xx2200000036 Arrange the cable package in axis 6. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 223 Refitting the process hub Action Note For robots with air hoses Reconnect the air hoses. xx2200000031 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 224 Grease: 3HAC029132-001 moving area of the package. Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 225 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 226: Replacing The Wrist Unit
The wrist unit is located as shown in the figure. xx2200000006 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 227 If no previous reference values exist, and 4600. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 228 Removing the covers Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 229 • R2.C1 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2200000032 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 230 Pulling out the cable package from axis 5 Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 231 The bracket cannot be removed completely until the cablings are removed from the plate. xx2200000038 Cut the cable strap. xx2200000039 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 232 Make sure axes are well supported before loosening timing belts. Loosen the screws and move the motor slightly to slacken the timing belt. xx2200000042 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 233 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2200000040 Remove the screws and washers. xx2200000044 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 234 R1.MP on page DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 235 R1.MP according to the section Supplying power to connector R1.MP on page Route the cable package into the wrist unit. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 236 - pressure relief pipe connector Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 237 Refit the screws and washers. Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (2 pcs) Note Do not tighten the screws yet. xx2200000044 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 238 Do not insert the entire screw to the hole. The screw shall be installed with proper force to avoid shaft rotation. xx2200000547 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 239 R1.MP according to the section Supplying power to connector R1.MP on page Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 240 Reconnecting the axis-6 motor connectors Action Note Apply grease to the cable package, cover all Grease: 3HAC029132-001 moving area of the package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 241 Reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx2200000035 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 242 Grease: 3HAC029132-001 moving area of the package. Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 243 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 244: Motors And Drive Units
5.5 Motors and drive units 5.5 Motors and drive units Introduction Only axis-2 drive unit, axis-3 motor and axis-5 motor of IRB 1010 are available to replace as spare parts. For details about the replacement procedure, see, • Replacing the axis-2 drive unit on page 245 •...
Page 245: Replacing The Axis-2 Drive Unit
The axis-2 drive unit is located as shown in the figure. xx2200000007 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 246 If no previous reference values exist, and 4600. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 247 Removing the covers Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 248 Removing drive units will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing drive units. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 249 Remove the screws (12 pcs) securing the axis-2 drive unit to the axis-1 assembly unit. CAUTION Do not remove the innermost screws (16 pcs). xx2200000066 xx2200000068 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 250 • the screw holes (marked on the red circle) on the drive unit are through-holes. xx2200000543 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 251 Refit the drive unit to the axis 3-4 assembly unit. Flange socket head screw, M3x12 12.9 Lafre 2C2B/FC6.9+PrO- COat111, 3HAB3412-312 (11 pcs) Tightening toroque: 1.5 Nm xx2200000065 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 252 Refitting the swing top cover Action Note Check the cooling pad. Cooling pad for axis-2 motor: 3HAC071021-001 Replace if damaged. xx2200000122 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 253 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 254: Replacing The Axis-3 Motor
The axis-3 motor is located as shown in the figure. xx2200000008 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 255 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 256 Remove the covers. • Lower arm cover, left (A) • Lower arm cover, right (B) xx2200000551 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 257 Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 258 Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before remov- ing motors. Remove the screws. xx2200000058 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 259 Refit the screws and washers. Flange socket head screw, M3x8 12.9 Lafre 2C2B/FC6.9+PrO- COat111, 3HAB3412-308 (4 pcs) Note Do not tighten the screws yet. xx2200000058 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 260 14.1±1 N (for reference only) tial referenced force. Initial referenced force for new belt: 20.2±1 N xx2200000545 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 261 Apply grease to the cable package, cover all Grease: 3HAC029132-001 moving area of the package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 262 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 263: Replacing The Axis-5 Motor
The axis-5 motor is located as shown in the figure. xx2200000010 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1010 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 264 Preparations before removing the axis-5 motor Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 265 Removing the process hub Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 266 Disconnecting the axis-6 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 267 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 268 The bracket cannot be removed completely until the cablings are removed from the plate. xx2200000038 Cut the cable strap. xx2200000039 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 269 Make sure axes are well supported before loosening timing belts. Loosen the screws and move the motor slightly to slacken the timing belt. xx2200000042 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 270 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2200000040 Remove the screws and washers. xx2200000044 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 271 - pressure relief pipe connector Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 272 Refit the screws and washers. Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (2 pcs) Note Do not tighten the screws yet. xx2200000044 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 273 Do not insert the entire screw to the hole. The screw shall be installed with proper force to avoid shaft rotation. xx2200000547 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 274 R1.MP according to the section Supplying power to connector R1.MP on page Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 275 Reconnecting the axis-6 motor connectors Action Note Apply grease to the cable package, cover all Grease: 3HAC029132-001 moving area of the package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 276 Reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx2200000035 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 277 Grease: 3HAC029132-001 moving area of the package. Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 278 Recalibrate the robot. Calibration is detailed in section Calibration on page 279. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 279: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 280: Calibration Methods
Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 1010. It is the recommended method in order to achieve proper performance. The following routines are available for the Axis Calibration method: •...
Page 281 References Article numbers for the calibration tools are listed in the section Special tools on page 325. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 282: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be re-calibrated 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 283: Synchronization Marks And Axis Movement Directions
6.2.1 Synchronization marks and synchronization position for axes Introduction This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 1010 xx2200000179 Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 284: Calibration Movement Directions For All Axes
Positive directions are shown in the graphic below. Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below. Manual movement directions xx2200000178 Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 285: Updating Revolution Counters
The calibration options are displayed. Tap Revolution Counters. In the Selection column select the axes for which revolution counters need to be up- dated. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 286 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 305. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 287: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 288 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 289 Special requirement How to calibrate a suspended robot The IRB 1010 is fine calibrated floor standing in factory, prior to shipping. To calibrate a suspended robot, reference calibration must be used. Reference values for a suspended robot must be created with the robot mounted at its working position, not standing on a floor.
Page 290: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 291 If including the calibration tool with smaller outer diameter in a local periodic check system, the following measures should be checked. • Outer diameter within Ø5g5 mm. • Straightness within 0.005 mm. xx1600001142 Outer diameter Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 292: Installation Locations For The Calibration Tools
This is shown in the figure. xx2100002855 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 293 6 Calibration 6.4.3 Installation locations for the calibration tools Continued xx2100002856 xx2100002857 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 294 Used on axis 1 to axis 3. Protective plug for bushing 3HAC076804-001 Replace if damaged or missing. (OD φ5) Used on axis 5 and axis 6. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 295: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 296 Note For RobotWare 7, the mechanical unit page is displayed only if there is more than one mechan- ical unit available. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 297 6.4.4 Axis Calibration - Running the calibration procedure Continued Action Note The calibration method used at ABB factory for The FlexPendant will give all inform- each axis is shown, as well as calibration method ation needed to proceed with Axis used for the robot during last field calibration.
Page 298 6.4.4 Axis Calibration - Running the calibration procedure Continued Calibration tools in contact Axis 3 Axis 4 xx2200000184 xx2200000185 Axis 5 Axis 6 xx2200000187 xx2200000186 Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 299 If the standard calibration data for axes 4, 5 or 6 Calibrating with Wrist Optimiz- should be updated with wrist optimization, run the ation method on page 302. calibration routine Wrist Optimization. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 300: Reference Calibration
3 Read and note current axis 4 value in degrees (example: 96.3 degrees). 4 Manually jog, only axis 4, so that the manipulator is correctly positioned to the verification position. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 301 10 Check again against the verification position. 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 302: Calibrating With Wrist Optimization Method
3 Improved calibration data to the wrist axes is identified and presented. 4 Optimized positions for the wrist axes are presented. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 303 WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 304: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on one side of the base. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 305: Checking The Synchronization Position
If they do not, up- ization position for axes on page 283 date the revolution counters. Updating revolution counters on page 285. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
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Page 307: Troubleshooting
Check: been installed • the configuration files • connectors • options and their configuration • changes in the robot working space/movements. Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 308 The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 309: Oil And Grease Stains On Motors And Gearboxes
"cooling periods" into the your local ABB representative. application. • Overpressure created inside gearbox. Inspect all sealings and gaskets between motor and gearbox. Replace broken parts. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 310: Mechanical Noise Or Dissonance
Make sure the bearings are fitted correctly. Tighten the screws if a heat sink, fan, or metal sheet is loose. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 311: Manipulator Collapses On Power Down
Remove the motor from the gearbox to in- If found faulty, the motor must be replaced spect it from the drive side. as a complete unit. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
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Page 313: Decommissioning
See also Environmental information on page 314. Transportation Prepare the robot or parts before transport, this to avoid hazards. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 314: Environmental Information
8.2 Environmental information 8.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
Page 315 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 316: Scrapping Of Robot
• A used robot does not have the same performance as on delivery. Springs, brakes, bearings, and other parts might be worn or broken. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 317: Reference Information
9.1 Introduction 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 318: Applicable Standards
Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices) EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus- trial robots — Part 1: Robots Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 319: 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 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 320: Screw Joints
9.4 Screw joints 9.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 321 Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated Continues on next page Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 322 Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Lubricated with Molycote 1000, Gleitmo 603 or equivalent Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 323: 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 324: Standard Toolkit
Ratchet head for torque wrench 1/2 Hex socket head cap no. 2.5 socket 1/2" bit L=110 mm Small screwdriver T-handle with ball head Small cutting plier Plastic mallet Needle-nose plier Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 325: Special Tools
If the replacing procedure is not listed in the table below, only standard tools are needed for the procedure. Tools and equipment with spare part number: (These tools can be ordered from ABB) 24 VDC power supply 3HAC074119-001 Calibration tool box, Axis Calibration Delivered as a set of calibration tools.
Page 326 This page is intentionally left blank...
Page 327: Spare Parts
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.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRB 1010 3HAC081964-001 Revision: B...
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Page 329: Index
304 mechanical stops, 92 when to calibrate, 282 robot cabling, 90 calibration, Absolute Accuracy, 281 timing belts, 91 calibration manuals, 281 installation calibration marks, 283 Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 330 CAN, 318 release brakes, 32 start of robot in cold environments, 79 replacements, report, 103 steel replacing disposal, 314 axis-5 motor, 263 storage conditions, 40 Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 331 226 inspecting, 91 torques on foundation, 38 transportation, 313 troubleshooting replacing, 49 safety, 34 turning radius, 44 zero position checking, 305 Product manual - IRB 1010 3HAC081964-001 Revision: B © Copyright 2022 ABB. All rights reserved.
Page 334 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.

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