3HAC9112-1_revQ_en

Product specificationArticulated robot

IRB 2400/10IRB 2400/16IRB 2400/LM2004

Product specification

Articulated robot3HAC9112-1

Rev. QIRB 2400/10IRB 2400/16IRB 2400/L

M2004

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

©Copyright 2004 ABB All right reserved.

ABB ABRobotics Products

SE-721 68 VästeråsSweden

Table of Contents

Overview 5

1 Description 7

1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.1.2 Different robot versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.2 Safety/Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181.3.2 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191.3.3 Mounting the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

1.4 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231.4.2 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241.4.3 Maximum load and moment of inertia for full axis 5 movement . . . . . . . . . . . . . . . . . . . . . .281.4.4 Wrist torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

1.5 Mounting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301.5.1 Robot tool flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

1.6 Calibration and references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341.6.1 Fine calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341.6.2 Absolute Accuracy calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

1.7 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

1.8 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381.8.2 Performance according to ISO 9283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421.8.3 Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431.8.4 Stopping distance/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431.8.5 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

2 Specification of Variants and Options 45

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452.1.2 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452.1.3 Positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512.1.4 Track Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

2.2 Floor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .522.2.1 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .522.2.2 Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

2.3 Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .542.3.1 DressPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .542.3.2 Process equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .552.3.3 AW Safety options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .562.3.4 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

3 Accessories 59

3HAC9112-1 Rev.Q 3

Table of Contents

4 Rev.Q 3HAC9112-1

Overview

OverviewAbout this Product specification

It describes the performance of the manipulator or a complete family of manipulators in terms of:

• The structure and dimensional prints

• The fulfilment of standards, safety and operating requirements

• The load diagrams, mounting of extra equipment, the motion and the robot reach

• The integrated auxiliary equipments as that is: Customer Connections

• The specification of variant and options available

UsersIt is intended for:

• Product managers and Product personnel

• Sales and Marketing personnel

• Order and Customer Service personnel

ContentsPlease see Table of Contents on page 3.

Revisions

Revision Description

Revision 6 - The IRB 2400/L 5-kg version cancelled- New values for Performance Acc. to ISO 9283 added- M2000 cancelled.

Revision G - Option 287-5 Wash removed

Revision H - Chapter Calibration and references added- Footnote added for “Pose accuracy”

Revision J - Arc welding added in Specification of Variants and Options

Revision K - Changes in chapter Standards - Directions of forces

Revision L - An extended load diagram for IRB 2400/16 is added- Warranty information for Load diagrams

Revision M - Maximum load and moment of inertia for full axis 5 movement- Wrist torque

Revision N - Changes for Calibration data- Work range- Explanation of ISO values (new figure and table)- Stopping distance- Changes in chapter Specification of Variants and Options, Track Motion and Process equipment- User documentation on DVD

Revision P - General update for 9.1 release

Revision Q - Updated/corrected Clean Room classes

3HAC9112-1 Rev.Q 5

Overview

Complementary Product specifications

Product specification Description

Controller IRC5 with FlexPendant, 3HAC021785-001

Controller Software IRC5

RobotWare 5.12, 3HAC022349-001

Robot User Documen-tation

IRC5 and M2004, 3HAC024534-001

6 Rev.Q 3HAC9112-1

1 Description1.1.1 Introduction

1 Description

1.1 Structure

1.1.1 Introduction

GeneralIRB 2400 is a 6-axis industrial robot, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has an open structure that is specially adapted for flexible use, and can communicate extensively with external systems.

Foundry Plus robotsThe IRB 2400F/10 and IRB 2400F/16 have the FoundryPlus protection.The Foundry Plus option is designed for harsh environments where the robot is exposed to sprays of coolants, lubricants and metal spits that are typical for die cast-ing applications or other similar applications. The Foundry Plus robot is painted with two-component epoxy on top of a special primer for excellent corrosion protection. To further improve the corrosion protection additional rust preventive are applied to exposed areas. The entire robot is IP67 compliant according to IEC 60529 - from base to wrist, which means that the electrical compartments are virtually sealed against liquid and solid contaminants. Among other things all sensitive parts are highly protected.Foundry Plus features:

• Improved sealing to prevent damp from penetrating into cavities• Additional protection of cabling and electronics• Special covers protecting cavities• Special connectorsThe Foundry Plus robot can be cleaned with adequate washing equipment.

Clean Room robotsThe clean room robots are going through a special manufacturing and painting process and are cleaned before shipment to reduce the emission of particles to a minimum.See chapter Specification of Variants and Options for options not selectable together with Clean Room.

Operating systemThe robot is equipped with the IRC5 controller and robot control software, RobotWare RW. RobotWare RW supports every aspect of the robot system, such as

3HAC9112-1 Rev.Q 7


motion control, development and execution of application programs communication etc. See Product specification - Controller IRC5 with FlexPendant.Safety standards require a conroller to be connected to the robot.For additional functionality, the robot can be equipped with optional software for application support - for example gluing and arc welding, communication features - network communication - and advanced functions such as multitasking, sensor control etc. For a complete description on optional software, see Product specification - Controller software IRC5/RobotWare Options.

8 Rev.Q 3HAC9112-1


Manipulator axes

Figure 1 The IRB 2400 manipulator has 6 axes.

3HAC9112-1 Rev.Q 9

1 Description1.1.2 Different robot versions

1.1.2 Different robot versions

GeneralThe IRB 2400 is available in three versions and all versions can be mounted inverted. IRB 2400/10 can also be wall mounted.

Definition of version designationIRB 2400 / Version.

Manipulator weight

Other technical data

Robot type Handling capacity (kg) Reach (m)

IRB 2400/10 10 kg 1.55 m

IRB 2400/16 16 kg (20 kg with some limita-tions, see chapter 1.4)

1.55 m

IRB 2400/L 7 kg 1.80 m

Prefix Description

Version L Long arm

Weight

Manipulator 380 kg

Data Description Values

Airborne noise level The sound pressure level out-side the working space

< 70 dB (A) Leq (acc. to Machinery directive 89/392 EEC)

10 Rev.Q 3HAC9112-1


Power consumptionPath E1-E2-E3-E4 in the ISO Cube, maximum load.

Figure 2 Path E1-E2-E3-E4 in the ISO Cube, maximum load.

Speed [mm/s] Power consumption [kW]

Max. 0.61 - 0.67

1000 0.46 - 0.50

500 0.40 - 0.44

100 0.37 - 0.39

3HAC9112-1 Rev.Q 11


Dimensions for IRB 2400/L

Figure 3 View of the manipulator from the side, rear and above (dimensions in mm).

12 Rev.Q 3HAC9112-1


Dimensions for IRB 2400/10 and IRB 2400/16

Figure 4 View of the manipulator from the side, rear and above (dimensions in mm).

3HAC9112-1 Rev.Q 13

1 Description1.2.1 Standards

1.2 Safety/Standards

1.2.1 Standards

The robot conforms to the following standards:

EN-Standards Description

EN ISO 12100-1 Safety of machinery, terminology

EN ISO 12100-2 Safety of machinery, technical specifications

EN 954-1 Safety of machinery, safety related parts of control systems

EN 60204 Electrical equipment of industrial machines

EN ISO 60204-1:2006 Safety of machinery - Electrical equipment of machines

EN ISO 10218-1:2006a

a. There is a deviation from paragraph 6.2 in that only worst case stop distances andstop times are documented.

Robots for industrial environments - Safety requirements

EN 61000-6-4 (option) EMC, Generic emission

EN 61000-6-2 EMC, Generic immunity

IEC-Standards Description

IEC 60529 Degrees of protection provided by enclosures

ISO-Standards Description

ISO 9409-1 Manipulating industrial robots, mechanical interface

ISO 9787 Manipulating industrial robots, coordinate systems and motions

Standards Description

ANSI/RIA R15.06/1999 (option)

Safety Requirements for Industrial Robots and Robot Systems

ANSI/UL 1740-1998 (option)

Safety Standard for Robots and Robotic Equipment

CAN/CSA Z 434-03 (option)

Industrial Robots and Robot Systems - General Safety Require-ments

14 Rev.Q 3HAC9112-1


The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives.

Safety function Description

The Service Information System (SIS)

The service information system gathers information about the robot’s usage and determines how hard the robot is used. The usage is characterized by the speed, the rotation angles and the load of every axis.With this data collection, the service interval of every individual robot of this generation can be predicted, optimized and service activities planned ahead. The collection data is available via the FlexPendant or the network link to the robot.The Process Robot Generation is designed with absolute safety in mind. It is dedicated to actively or passively avoid collisions and offers the highest level of safety to the operators and the machines as well as the surrounding and attached equipment. These features are presented in the active and passive safety system.The time the robot is in operation (brakes released) is indicated on the FlexPendant. Data can also be monitored over network, using e.g. WebWare.

The Active Safety System Description

General The active safety system includes those software features that maintain the accuracy of the robot’s path and those that actively avoid collisions which can occur if the robot leaves the programmed path accidentally or if an obstacle is put into the robot’s path.

The Active Brake System (ABS)

All robots are delivered with an active brake system that supports the robots to maintain the programmed path in General Stop (GS), Auto Stop (AS) and Superior Stop (SS).The ABS is active during all stop modes, braking the robot to a stop with the power of the servo drive system along the programmed path. After a specific time the mechanical brakes are activated ensuring a safe stop.The stopping process is in accordance with a class 1 stop. The maximum applicable torque on the most loaded axis determines the stopping distance.In case of a failure of the drive system or a power interruption, a class 0 stop turns out. Emergency Stop (ES) is a class 0 stop. All stops (GS, AS, SS and ES) are reconfigurable.While programming the robot in manual mode, the enabling device has a class 0 stop.

3HAC9112-1 Rev.Q 15


The Self Tuning Performance (STP)

The Process Robot Generation is designed to run at different load configurations, many of which occur within the same program and cycle.The robot’s installed electrical power can thus be exploited to lift heavy loads, create a high axis force or accelerate quickly without changing the configuration of the robot.Consequently the robot can run in a “power mode” or a “speed mode” which can be measured in the respective cycle time of one and the same program but with different tool loads. This feature is based on QuickMoveTM.The respective change in cycle time can be measured by running the robot in NoMotionExecution with different loads or with simulation tools like RobotStudio.

The Electronically Stabilised Path (ESP)

The load and inertia of the tool have a significant effect on the path performance of a robot. The Process Robot Generation is equipped with a system to electronically stabilize the robot’s path in order to achieve the best path performance.This has an influence while accelerating and braking and consequently stabilizes the path during all motion operations with a compromise of the best cycle time. This feature is secured through TrueMoveTM.

Over-speed protection The speed of the robot is monitored by two independent computers.

Restricting the working space

The movement of each axis can be restricted using software limits.As options axes 1-2 can also be restricted by means of mechanical stops and axis 3 by an electrically switch.

Collision detection (option)

In case of an unexpected mechanical disturbance, such as a collision, electrode sticking, etc., the robot will detect the collision, stop on the path and slightly back off from its stop position, releasing tension in the tool.

The Passive Safety System Description

General The Process Robot Generation has a dedicated passive safety system that by hardware construction and dedicated solutions is designed to avoid collisions with surrounding equipment. It integrates the robot system into the surrounding equipment safely.

Compact robot arm design

The shape of the lower and upper arm system is compact, avoiding interference into the working envelope of the robot.The lower arm is shaped inward, giving more space under the upper arm to re-orientate large parts and leaving more working space while reaching over equipment in front of the robot.The rear side of the upper arm is compact, with no components projecting over the edge of the robot base even when the robot is moved into the home position.

Moveable mechanical limitation of main axes (option)

Axes 1-2 can be equipped with moveable mechanical stops, limiting the working range of every axis individually. The mechanical stops are designed to withstand a collision even under full load.

The Active Safety System Description

16 Rev.Q 3HAC9112-1


Electronic Position Switches (EPS) on up to 7 axes (option)

EPS offers axes position status signals, fulfilling applicable regulations for personnel safety. Five outputs can each be configured to reflect the position of a single axis or a combination of axes. For each output, the range for each included axis can be set arbitrarily.

The Internal Safety Concept Description

General The internal safety concept of the Process Robot Generation is based on a two-channel circuit that is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage.

Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery - safety related parts of control Systems - Part 1.

Selecting the operating mode

The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the FlexPendant, i.e. not by any external equipment.

Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.). The speed limitation applies not only to the TCP (Tool Center Point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot.

Three position enabling device

The enabling device on the FlexPendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate.

Safe manual movement

The robot is moved using a joystick instead of the operator having to look at the FlexPendant to find the right key.

Emergency stop There is one emergency stop push button on the controller and another on the FlexPendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit.

Safeguarded space stop

The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself.

Delayed safeguarded space stop

A delayed stop gives a smooth stop. The robot stops the same way as at a normal program stop with no deviation from the programmed path. After approx. 1 second the power supplied to the motors is shut off.

Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. When the button is released the robot will stop. The hold-to-run function makes program testing safer.

Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratories Inc.) tough requirements for fire safety.

Safety lamp (option) As an option, the robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.

The Passive Safety System Description

3HAC9112-1 Rev.Q 17


1.3 Installation

1.3.1 Introduction

GeneralThe same version of the robot can either be mounted on the floor or inverted. An end effector, max. weight 7, 10 or 16 kg including payload, can be mounted on the robot’s mounting flange (axis 6) depending on the robot version.See section 1.4 Load diagrams.

Other equipmentOther equipment can be mounted on the upper arm, max. weight 11 kg or 12 kg, and on the base, max. weight 35 kg. Holes for mounting extra equipment, see chapter 1.5 Mounting equipment and Figure 12 and Figure 13.

Working rangeThe working range of axes 1-2 can be limited by mechanical stops and axis 3 by limit switches. Electronic Position Switches can be used on all axes for position indicator of manipulator.

18 Rev.Q 3HAC9112-1

1 Description1.3.2 Operating requirements

1.3.2 Operating requirements

Protection standards

Explosive environmentsThe robot must not be located or operated in an explosive environment.

Ambient temperature

Relative humidity

Robot Version/Protection Standard Protection standard IEC60529

Standard and Clean Room Manipulator IP54

IRB 2400F/L and C/LManipulatorWristConnectors

IP55IP67IP67

IRB 2400F/10, F/16Manipulator

IP67, Steam washable

Description Standard/Option Temperature

Manipulator during opera-tion

Standard + 5°C (41°F) to + 45°C (113°F)

For the controller Standard/Option See Product specification - Con-troller IRC5 with FlexPendant

Complete robot during transportation and storage

Standard - 25°C (-13°F) to + 55°C (131°F)

For short periods (not exceeding 24 hours)

Standard up to + 70°C (158°F)

Description Relative humidity

Complete robot during transportation and storage

Max. 95% at constant temperature

Complete robot during operation Max. 95% at constant temperature

3HAC9112-1 Rev.Q 19

1 Description1.3.3 Mounting the manipulator

1.3.3 Mounting the manipulator

Maximum load in relation to the base coordinate system. See Figure 6.

IRB 2400/L

IRB 2400/10 and IRB 2400/16

Endurance load in operation Max. load at emergency stop

Force xy ± 1700 N ± 2100 N

Force z floor mounting

+ 4100 ±1100 N + 4100 ± 1400 N

Force z inverted mounting

- 4100 ±1100 N - 4100 ± 1400 N

Torque xy ± 3000 Nm ± 3400 Nm

Torque z ± 450 Nm ± 900 Nm

Endurance load in operation Max. load at emergency stop

Force xy ± 2000 N ± 2600 N

Force z floor mounting

+ 4100 ± 1400 N + 4100 ± 1900 N

Force z inverted mounting

- 4100 ± 1400 N - 4100 ± 1900 N

Torque xy ± 3400 Nm ± 4000 Nm

Torque z ± 550 Nm ± 900 Nm

20 Rev.Q 3HAC9112-1


Figure 5 Directions of forces.

Note regarding Mxy and Fxy

The bending torque (Mxy) can occur in any direction in the XY-plane of the base coordinate system.The same applies to the transverse force (Fxy).

3HAC9112-1 Rev.Q 21


Figure 6 Hole configuration (dimensions in mm).

Pos Description

A Z = center line axis 1

B The same dimensions

C View from the bottom of the base

22 Rev.Q 3HAC9112-1


1.4 Load diagrams

1.4.1 Introduction

If incorrect load data and/or loads outside load diagram is used the following parts can be damaged due to overload:

• motors

• gearboxes

• mechanical structure

It is very important to always define correct actual load data and correct payload of the robot. Incorrect definitions of load data can result in overloading of the robot.

In the robot system is the service routine LoadIdentify available, which allows the user to make an automatic definition of the tool and load, to determine correct load parameters. Please see Operating Manual - IRC5 with FlexPendant, art. No. 3HAC16590-1, for detailed information.

Robots running with incorrect load data and/or with loads outside load diagram will not be covered by the robot warranty.

3HAC9112-1 Rev.Q 23

1 Description1.4.2 Diagrams

1.4.2 Diagrams

IRB 2400/L

Figure 7 Maximum weight permitted for load mounting on the mounting flange at different positions (cen-ter of gravity).

Description

Z See the above diagram and the coordinate system in the Product specification - IRC5 with FlexPendant

L Distance in X -Y plane from Z - axis to the center of gravity

J Maximum own moment of inertia on the total handling weight = ≤ 0.012 kgm2

24 Rev.Q 3HAC9112-1


IRB 2400/10


Description




3HAC9112-1 Rev.Q 25


IRB 2400/16


Description




26 Rev.Q 3HAC9112-1


IRB 2400/16 Extended load diagramBelow is an extended load diagram for IRB 2400/16, payload 20 kg.

Figure 10 Maximum weight permitted for load mounting on the mounting flange at different positions (center of gravity).

No extra load on wrist, see Figure 14.

Description




3HAC9112-1 Rev.Q 27

1 Description1.4.3 Maximum load and moment of inertia for full axis 5 movement

1.4.3 Maximum load and moment of inertia for full axis 5 movement

GeneralTotal load given as: Mass in kg, center of gravity (Z and L) in meter and moment of inertia (Jox, Joy, Joz ) in kgm2 . L= √(X2 + Y2), see Figure 11.

Full movement of Axis 5 (±115º)5

Figure 11 Moment of inertia when full movement of axis 5.

Axis Robot Type Maximum momemt of inertia

5 IRB 2400L J5 = Mass x ((Z + 0.065)2 + L2) + max (J0x, J0y) ≤ 0.65 kgm2

6 IRB 2400L J6 = Mass x L2 + J0Z ≤ 0.31 kgm2


5 IRB 2400/10 J5 = Mass x ((Z + 0.085)2 + L2) + max (J0x, J0y) ≤ 1.15 kgm2

6 IRB 2400/10 J6 = Mass x L2 + J0Z ≤ 0.70 kgm2


5 IRB 2400/16 J5 = Mass x ((Z + 0.085)2 + L2) + max (J0x, J0y) ≤ 1.85 kgm2

6 IRB 2400/16 J6 = Mass x L2 + J0Z ≤ 1.05 kgm2

Pos Description

A Center of gravity

Description

Jox, Joy, Joz Max. moment of inertia around the X, Y and Z axes at center of gravity.

28 Rev.Q 3HAC9112-1

1 Description1.4.4 Wrist torque

1.4.4 Wrist torque

The table below shows the maximum permissible torque due to payload..

Note! The values are for reference only, and should not be used for calculating permitted load offset (position of center of gravity) within the load diagram, since those also are lim-ited by main axes torques as well as dynamic loads. Also arm loads will influence the per-mitted load diagram. For finding the absolute limits of the load diagram, please contact your local ABB organization.

Robot type Max wrist torque axis 4 and 5

Max wrist torque axis 6

Max torque valid at load

IRB 2400L 12.4 Nm 5.84 Nm 7 kg

RB 2400/10 20.6 Nm 9.81 Nm 10 kg

RB 2400/16 33.0 Nm 15.7 Nm 16 kg

3HAC9112-1 Rev.Q 29


1.5 Mounting equipmentThe robot is supplied with tapped holes on the upper arm and on the base for mounting extra equipment.

IRB 2400/L

Figure 12 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).

Pos Description

A The rear side of the manipulator

M8 (2x)Depth 14

400

300

Max. 10kgA A

150135

CL

400 470D=2

00

170

30

Max. 1kg

A - A

67

D D

37

70 (2x)62

37

D - D

Depth 9M5 (2x)

D=50150

Max. 35 kg total

M8 (3x) R=92Depth 16

120o (3x)

B

B

B - B

38o

C - C

C

C

120o (3x)

38o


(A)

30 Rev.Q 3HAC9112-1


IRB 2400/10 and IRB 2400/16


Pos Description

A The rear side of the manipulator

400

300

3570

65 177

M8 (3x)Depth of thread 14

A A

M6 (2x)

110

25

100

200

300 450

D=240

Max. 2kg

A - A

M5 (2x)

22

43

Max. 10kg

78 90

38o


C - C

120o (3x)

D=50150

Max. 35 kg total

B

B

C

C(A)


120o (3x)

B - B38o

3HAC9112-1 Rev.Q 31


IRB 2400/16 with payload 20 kg


Pos Description

A No extra load on wrist

B The rear side of the manipulator

300

100

3570

65 177

M8 (3x)Depth of thread 14

A A

100

200

A - A Max. 10kg

90

38o


C - C

120o (3x)

D=50150

Max. 35 kg total

B

B

C

C

(B)


120o (3x)

B - B

38o

(A)

32 Rev.Q 3HAC9112-1

1 Description1.5.1 Robot tool flange

1.5.1 Robot tool flange

IRB 2400/L

Figure 15 The mechanical interface, mounting flange (dimensions in mm).

IRB 2400/10 and IRB 2400/16

Figure 16 The mechanical interface, mounting flange (dimensions in mm).

45oD=6 H7

M6 (4x)

R=20

A

A

Ø 0.05 B

(4x)90o 6

D=2

5

9

A - A

D=5

0 h

8

B

H8

+0.0

27-0

+0 -0.0

39

+0.012-0

7

D=3

1,5

D=6+0.012-0

M6 (6x)

60o

30o

A - A

A

A

R=25

Ø 0.05 B

D=6

3 h

8

B

5x

H7, depth min 8

H8

+0.0

39-0

+0 -0.0

46

10

3HAC9112-1 Rev.Q 33

1 Description1.6.1 Fine calibration

1.6 Calibration and references

1.6.1 Fine calibration

GeneralFine calibration is made using the Calibration Pendulum, please see Operating manual - Calibration Pendulum.

Figure 17 All axes in zero position.

Calibration

Calibration Position

Calibration of all axes All axes are in zero position

Calibration of axis 1 and 2 Axis 1 and 2 in zero position

Axis 3 to 6 in any position

Calibration of axis 1 Axis 1 in zero position

Axis 2 to 6 in any position

34 Rev.Q 3HAC9112-1

1 Description1.6.2 Absolute Accuracy calibration

1.6.2 Absolute Accuracy calibration

GeneralRequires RobotWare option Absolute Accuracy, please see Product specification - Controller software IRC5 for more details.

The calibration conceptAbsolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute accuracy of better than ± 1 mm in the entire working range.Absolute accuracy compensates for:

• Mechanical tolerances in the robot structure

• Deflection due to load

Absolute accuracy calibration is focusing on positioning accuracy in the cartesian coordinate system for the robot. It also includes load compensation for deflection caused by the tool and equipment. Tool data from robot program is used for this purpose. The positioning will be within specified performance regardless of load.

Calibration dataThe user is supplied with robot calibration data (compensation parameters saved on the manipulator SMB) and a certificate that shows the performance (Birth certifi-cate). The difference between an ideal robot and a real robot without AbsAcc can typically be 8 mm, resulting from mechanical tolerances and deflection in the robot structure.If there is a difference, at first start-up, between calibration data in controller and the robot SMB, correct by copying data from SMB to controller.

3HAC9112-1 Rev.Q 35

1 Description1.6.2 Absolute Accuracy calibration

Absolute Accuracy optionAbsolute Accuracy option is integrated in the controller algorithms for compensation of this difference and does not need external equipment or calculation.Absolute Accuracy is a RobotWare option and includes an individual calibration of the robot (mechanical arm).Absolute Accuracy is a TCP calibration in order to Reach (m) a good positioning in the Cartesian coordinate system.

Figure 18 The Cartesian coordinate system.

Production dataTypical production data regarding calibration are:

RobotPositioning accuracy (mm)

Average Max % Within 1 mm

IRB 2400L 0,40 0,80 100

IRB 2400/10IRB 2400/16

0,30 0,70 100

36 Rev.Q 3HAC9112-1


1.7 Maintenance and Troubleshooting

1.7.1 Introduction

GeneralThe robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible:

• Maintenance-free AC motors are used.

• Oil is used for the gear boxes.

• The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change.

The following maintenance is required:• Changing filter for the drive system cooling every year.

• Changing batteries every 3rd year.

• Changing oil in the wrist after the first year and then every 5th year.

MaintenanceThe maintenance intervals depend on the use of the robot. For detailed information on maintenance procedures, see Maintenance section in the Product Manual.

3HAC9112-1 Rev.Q 37


1.8 Robot Motion

1.8.1 Introduction

IRB 2400/LThe working area is the same for both floor and inverted mounting.

Type of motion Range of movement

Axis 1 Rotation motion +180° to -180°

Axis 2 Arm motion +110° to -100°


Axis 4 Wrist motion +185° to -185°

Axis 5 Bend motion +115° to -115°

Axis 6 Turn motion +400° to -400° +300 rev.a to -300 rev. Max.b

a. rev. = Revolutionsb. The default working range for axis 6 can be extended by changing parameter val-

ues in the software.Option 610-1 “Independent axis” can be used for resetting the revolution counterafter the axis has been rotated (no need for “rewinding” the axis).

38 Rev.Q 3HAC9112-1


Figure 19 The extreme positions of the robot arm (dimensions in mm).

Positions at wrist center (mm) and Angle (degrees) for IRB 2400/L:

Pos Description

A Wrist center

B Positions at wrist center (mm) and angle (degrees) see the following table

Position no (see Figure 19)

Position (mm) X

Position (mm) Z

Angle (degrees) Axis 2


0 970 1620 0 0

1 404 2298 0 -60

2 602 745 0 65

3 1577 -246 110 -60

4 400 -403 110 24.5

5 -1611 623 -100 -60

6 -115 1088 -100 65

R=570R=40

0

Pos 4

Pos 4

Pos 5

Pos 6

Pos 2

Pos 1

Pos 3

R=521

+++

Axis 4Axis 3

Axis 5 Axis 6

Axis 2

Axis 1

100

1810

1702

3421

2885

560

X

Z

+

Pos 0 (A)

+

(B)

3HAC9112-1 Rev.Q 39


IRB 2400/10 and IRB 2400/16The working area is the same for both floor and inverted mounting.For wall mounted 10 kg version axis 1 rotation is limited to ±30º.

Type of motion Range of movement

Axis 1 Rotation motiona

a. +30° to -30° for wall mounted 10 kg version.

+180° to -180°



Axis 4 Wrist motion +200° to -200° (Unlimited as optional)

Axis 5 Bend motion +120° to -120°

Axis 6 Turn motion +400° to -400° +250 rev.b to -250 rev. Max.c

b. rev. = Revolutionsc. The default working range for axis 6 can be extended by changing parameter values in

the software.Option 610-1 “Independent axis” can be used for resetting the revolution counter afterthe axis has been rotated (no need for “rewinding” the axis).

40 Rev.Q 3HAC9112-1


Figure 20 The extreme positions of the robot arm (dimensions in mm).

Positions at wrist center (mm) and Angle (degrees) for IRB 2400/10 and IRB 2400/16:

Pos Description

A Wrist center

B Positions at wrist center (mm) and angle (degrees) see the following table

Position no (see Figure 20)

Position (mm) X

Position (mm) Z



0 855 1455 0 0

1 360 2041 0 -60

2 541 693 0 65

3 1351 -118 110 -60

4 400 -302 110 18.3

5 -1350 624 -100 -60

6 -53 1036 -100 65

Pos 4

Pos 5

Pos 6

Pos 2

Axis 3

Axis 5 Axis 6

Axis 2

Pos 3

+ + ++

Axis 4

+R=448

Pos 1

Axis 1

1441

100

1550

393

2458

2900

X

Z Pos 0 (A)

R=570R=40

0

Pos 4(B)

3HAC9112-1 Rev.Q 41

1 Description1.8.2 Performance according to ISO 9283

1.8.2 Performance according to ISO 9283

GeneralAt rated load and 1.6 m/s velocity on the inclined ISO test plane with all six robot axes in motion.The figures for AP, RP, AT and RT are mesured according to Figure 21.

Figure 21 Explanation of ISO values.

The above values are the range of average test results from a number of robots.

Pos Description Pos Description

A Programmed position E Programmed path

B Mean position at program execution D Actual path at program execution

AP Mean distance from programmed position

AT Max deviation from E

RP Tolerance of posiotion B at repeated positioning

RT Tolerance of the path at repeated program execution

IRB IRB 2400/L IRB 2400/10 IRB 2400/16

Description Values

Pose repeatability, RP (mm) 0.07 0.03 0.03

Pose accuracy, APa (mm)

a. AP according to the ISO test above, is the difference between the teached position(position manually modified in the cell) and the average position obtained duringprogram execution.

0.04 0.03 0.03

Linear path repeatability, RT (mm) 0.11 0.11 0.15

Linear path accuracy, AT (mm) 0.78 0.33 0.41

Pose stabilization time, Pst (s) within 0.4 mm of the position

0.14 0.15 0.22

42 Rev.Q 3HAC9112-1

1 Description1.8.3 Velocity

1.8.3 Velocity

Supervision is required to prevent overheating in applications with intensive and frequent movements.

ResolutionApprox. 0.01o on each axis.

1.8.4 Stopping distance/time

Stopping distance/time for emergency stop (category 0), program stop (category 1) and at mains power supply failure at max speed, max streched out and max load, categories according to EN 60204-1. All results are from tests on one moving axis. All stop distances are valid for floor mounted robot, without any tilting.

Axis no. IRB 2400/L IRB 2400/10 IRB 2400/16

1 150°/s 150°/s90°/sa

a. For wall mounted 10 kg version

150°/s

2 150°/s 150°/s90°/sa

150°/s

3 150°/s 150°/s90°/sa

150°/s

4 360°/s 360°/s 360°/s

5 360°/s 360°/s 360°/s

6 450°/s 450°/s 450°/s

Robot TypeCategory 0 Category 1 Main power failure

Axis A B A B A B

IRB 2400L 1 35.2 0.47 59 0.70 46.2 0.54

2 13.9 0.18 26.2 0.35 22.1 0.24

3 10.9 0.15 26.4 0.30 21.4 0.21


Axis A B A B A B

IRB 2400/10 1 39.7 0.52 43.3 0.55 51.4 0.60

2 13.5 0.18 16.4 0.19 23.7 0.25

3 16.3 0.22 18.7 0.24 26.8 0.29

3HAC9112-1 Rev.Q 43

1 Description1.8.5 Signals

1.8.5 Signals


Axis A B A B A B

IRB 2400/16 1 48.4 0.62 71.0 0.88 56.1 0.67

2 16.8 0.21 28.8 0.36 23.6 0.26

3 24.9 0.30 37.9 0.44 32.3 0.35

Description

A Distance in degrees

B Stop time (s)

For more information of air and signals for extra equipment to upper arm, see Application Interface in chapter 2 Specification of Variants and Options.

44 Rev.Q 3HAC9112-1

2 Specification of Variants and Options2.1.1 General

2 Specification of Variants and Options

2.1 Introduction

2.1.1 General

The different variants and options for the IRB 2400 are described below.The same numbers are used here as in the Specification form. For controller options, see Product specification - Controller IRC5 with FlexPendant, and for software options, see Product specification - Controller software IRC5/RobotWare.

2.1.2 Manipulator

Variants

Manipulator color

Option IRB Type Handling capacity (kg) / Reach (m)

435-7 IRB 2400/10 10/1.55

435-8 IRB 2400/16 16 (20 kg with some limitations, see chapter 1.4)/1.55

435-9 IRB 2400/L 7/1.80

Option Description

209-1 The robot is painted in color ABB Orange.

209-2 The robot is painted in white color.

209-4--192 The manipulator is painted with the chosen RAL-color.

3HAC9112-1 Rev.Q 45

2 Specification of Variants and Options2.1.2 Manipulator

Protection

Mounting position

Option Description

287-4 Standard

287-3 FoundryPlus

The Foundry Plus option is designed for harsh environments where the robot is exposed to sprays of coolants, lubricants and metal spits that are typical for die casting applications or other similar applica-tions. The Foundry Plus robot is painted with two-component epoxy on top of a special primer for excellent corrosion protection. To further improve the corrosion protection additional rust preven-tive are applied to exposed areas. The entire robot is IP67 compliant according to IEC 60529 - from base to wrist, which means that the electrical compartments are virtually sealed against liquid and solid contaminants. Among other things all sensitive parts are highly protected.Foundry Plus features:

• Improved sealing to prevent damp from penetrating into cavities

• Additional protection of cabling and electronics• Special covers protecting cavities• Special connectorsThe Foundry Plus robot can be cleaned with adequate washing equipment.The robot is labeled with “Foundry” (IRB 2400F/L) or “Foundry Plus” (IRB 2400F/10 and F/16).

287-1 Clean Room

The robot is labeled with “Clean Room”.The following options are NOT selectable together with option 287-1:

• 435-2 IRB 2400L• 218-6 At upper arm axis 4

The robot has special paint quality and is always in white color

Option Description

224-1 Floor mounted

224-2 Inverted

224-3 Wall mounteda

a. For 10 kg version, limited axis 1 rotation to ± 30° and reduced speed axis 1, 2 and 3 to 90°/s.

46 Rev.Q 3HAC9112-1


Application interfaceAir supply and signals for extra equipment to upper arm.For connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling, one FCI UT07 14 12SH44N connector and one FCI UT07 18 23SH44N connector on the rear part of the upper arm.A hose for compressed air is also integrated into the manipulator. There is an inlet (R1/4”) at the base and an outlet (R1/4”) on the upper arm.

Signals 23 50 V, 250 mA

Power 10 250 V, 2 A

Air 1 Max. 8 bar, inner hose diameter 8 mm

3HAC9112-1 Rev.Q 47


Application interface connection to

Connector kitDetached connectors, suitable to the connectors for the application interface and position switches.The kit consists of connectors, pins and sockets.

Option Description

218-8 Integrated hose and cables for connection of extra equipment on the manipulator to the rear part of the upper arm.

218-6 Hose and cables for connection of extra equipment are extended to the wrist on the outside of the upper arm. Not possible on IRB 2400/L, option 435-9.

Option Description

16-1 Cabineta

a. Note! In a M2004 MultiMove application additional robots have no ControlModule. The screw terminals with internal cabling are then delivered separately tobe mounted in the main robot Control Module or in another encapsulation, forexample a PLC cabinet.

The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, to the the controller.Not together with option 218-3.

Option Description

431-1 For the connectors on the upper arm if application interface, option 218-8 or option 218-6.

239-1 For the connectors on the foot if connection to manipulator, option 16-2.

426-1 For connection to position switches and connection to manipulator, option 271-2 and option position switch(es).

48 Rev.Q 3HAC9112-1


Safety lamp

Electronic Position Switches (EPS)The mechanical position switches indicating the position of the three main axes are replaced with electronic position switches for up to 7 axes, for increased flexibility and robustness. For more detailed information see Product specification - IRC5 with FlexPendant and Application Manual EPS, art. No. 3HAC027709-001.

Option Description

213-1 A safety lamp with an orange fixed light can be mounted on the manipulator.The lamp is active in MOTORS ON mode.The safety lamp is required on a UL/UR approved robot.

3HAC9112-1 Rev.Q 49


Working range limit - axis 1To increase the safety of the robot, the working range of axis 1 can be restricted.

Figure 22 Mounting area of the stops, axis 1.


Figure 23 Mounting positions of the stops, axis 2.

Option Description

28-1 Axis 1Two extra stops for restricting the working range. The stops can be mounted within the area from 50° to 140°. See Figure 22.

Option Description

32-1 Axis 2Stop lugs for restricting the working range. Figure 23 illustrates the mounting positions of the stops.

50 Rev.Q 3HAC9112-1

2 Specification of Variants and Options2.1.3 Positioners


2.1.3 Positioners

GeneralRegarding positioners, see Product Specification 3HAC028283-001.

2.1.4 Track Motion

Track Motion type

Additional travel length

Example of ordering a track motion RTT, with a requested travel length of 7.5 m:

In this case, option 1000-5 specify a track motion with a travel length of 1.7 m, option 1001-1 adds 6 meters to that, ending up with a total travel length of 7.7 m.

Option Description

34-1 Axis 3Equipment for electrically restricting the working range in increments of 5°

Option Type Description

1000-5 no AW For IRB 1600/2400 robot, with a travel length of 1.7 m. For for example material handling robot.

1000-6 for AW For IRB 1600/2400 robot, with a travel length of 1.7 m. For AW robot with Marthon-pac or Bobbin holder.

Option Description Note

1001-1 (1-18) Add travel length

Chose additional travel length in meter, above the min. length under Track Motion Type.The selection 1 adds 1m travel length, 2 adds 2m travel length and so on.......

1000-5 RTT with BobbinTrack Motion Type

1001-1 Add travel length6

3HAC9112-1 Rev.Q 51


Warranty

2.2 Floor cables

2.2.1 Manipulator

Manipulator cable length

Connection of Parallel communication


438-1 Standard Warranty Standard warranty is 18 months (1 1/2 years)

438-2 Standard + 12 months 18 + 12 months (2 1/2 years)

438-4 Standard + 18 months 18 + 18 months (3 years)

438-5 Standard + 24 months 18 + 24 months (3 1/2 years)

438-6 Standard + 6 months 18 + 6 months (2 years)

438-8 Stock Warranty Maximum 6 months postponed warranty starting from shipment date ABB Robotics Production unit (PRU) + Option 438-1. Warranty commences automatically after 6 months or from activation date of standard warranty. (See ABB Robotics BA Warranty Rules).

Option Lengths

210-2 7 m

210-3 15 m

210-4 22 m

210-5 30 m

Option Lengths

94-1 7 m

94-2 15 m

94-3 22 m

94-4 30 m

52 Rev.Q 3HAC9112-1

2 Specification of Variants and Options2.2.2 Positioner

2.2.2 Positioner

Positioner cable 1

Positioner cable 2

Positioner cable type

Weld return cable

Return cable

Option Lengths

1067-1 7 m

1067-2 10 m (Standard length)

1067-3 15 m

Option Lengths

1068-1 7 m

1068-2 10 m (Standard length)

1068-3 15 m


1048-1 Flexible Only available with one or two MTC 250/500/750/2000/5000

Option Lengths

1056-1 7 m

1056-2 7 m x 2

1056-3 10 m

1056-4 10 m x 2

1056-5 15 m

1056-6 15 m x 2


1057-1 OKC T-connection Choose quantity, 1-2

3HAC9112-1 Rev.Q 53

2 Specification of Variants and Options2.3.1 DressPack

2.3 Process

2.3.1 DressPack

Welding torch package

Process module

Installation kit

Option Description

878-2 Self cooled torch, iSTM-ABIROB A 22 degrees

878-3 Water cooled torch, iSTM-ABIROB W 22 degrees


768-1 Empty cabinet small

See Product Specification - Controller IRC5 with FlexPendant, chapter 2.2.1

768-2 Empty cabinet large See Product Specification - Controller IRC5 with FlexPendant, chapter 2.2.1

768-5 AWC / WeldGuide Only together with AristoMig 4000i/5000i, MigRob and TPS power sources.


715-1 Installation kit See Product Specification - Controller IRC5 with FlexPendant, chapter 2.2.1

54 Rev.Q 3HAC9112-1

2 Specification of Variants and Options2.3.2 Process equipment

2.3.2 Process equipment

Power source

Current/Hose set

Feed kit

Torch service


1029-13 AristoMig 4000i 400 V including wirefeederOnly together with option 878-2 or 878-3.

1029-14 AristoMig 5000i 400 V including wirefeederOnly together with option 878-2 or 878-3.


1030-4 7.5 m For external suspension mounting, not included.Only together with option 1029-13 or 1029-14.

1030-5 10 m Internal suspension mounting, hose package attatched to the robot base. Protective hose included. Only together with option 1029-13 or 1029-14.


1033-2 Marathon Pac Octagon

Liner for 250 kg Marathon Pac. Plastic hood for round Maraton-Pac included.

1033-3 Bobbin A 15 kg bobbin holder on the robot.


1037-1 ABB TSC ABB Torch Service Center.

1037-2 ABB TC96 ABB Torch cleaner.

1037-5 BullsEye BullsEye stand alone.

3HAC9112-1 Rev.Q 55

2 Specification of Variants and Options2.3.3 AW Safety options

2.3.3 AW Safety options

Working area

Operator panel

AW Safety interface

Lightbeam

Gate switch

Home position switch


1072-1 One working area

1072-2 Two working areas


1054-1 Operator panel 1 area

For one working area

1054-2 Operator panel 2 areas

For two working areas.

1054-3 2 x operators panel 2 areas

Two operator panels, one for each working area.


1058-1 Safety interface SIB, requires options 735-3 and 735-4.

1058-2 Active relay Active relay supervision (open relay).


1059-1 Lightbeam Qty 1 or 2, one working area requires one PC of ”two level light beams”.Two working areas rerquire two PCs of “two level light beams”.


1060-1 Gate switch

1060-2 Gate switch/ ext. reset


1061-1 Home position switch

Home position switch for IRB 1600/2400, one work-ing area.

56 Rev.Q 3HAC9112-1

2 Specification of Variants and Options2.3.4 Documentation

Station indication

Pre-reset unit

Activation unit

Extended EM stop

2.3.4 Documentation

DVD User Documentation


1062-1 Station indication Station indication for IRB 1600/2400, two working areas.


1063-1 Pre-reset unit Qty 1 or 2, one working area requires one PC of “Pre-reset”. Two working areas require two PCs of “Pre-reset”.


1064-1 Activation unit Qty 1 or 2, one requires one PC of “Activation unit”. Two working areas require two PCs of “Activation unit”.


1065-1 Extended EM stop Required when using external EM-stop push buttons and when ordering a dual arc system (two welding packages).


808-1 Documentation on DVD

See Product Specification - Robot User Documentation

3HAC9112-1 Rev.Q 57

2 Specification of Variants and Options2.3.4 Documentation

58 Rev.Q 3HAC9112-1

3 Accessories

3 AccessoriesGeneral

There is a range of tools and equipment available, specially designed for the robot.

Basic software and software options for robot and PCFor more information, see Product specification - Controller IRC5 with FlexPendant, and Product specification - Controller software IRC5/RobotWare.

Robot Peripherals• Track Motion

• Motor Units

3HAC9112-1 Rev.Q 59

3 Accessories

60 Rev.Q 3HAC9112-1

Index

Aaccessories, 59Active Brake System, 15active safety system, 15air supply, 47Application interface, 47

connection to, 48AW Safety options, 56

Activation unit, 57AW Safety interface, 56Extended EM stop, 57Gate switch, 56Home position switch, 56Lightbeam, 56Operator panel, 56Pre-reset unit, 57Station indication, 57Working area, 56

Ccalibration, 34, 35Collision detection, 16compact robot arm, 16Connector kit, 48cooling device, 10

Ddesign, 16Documentation, 57

EElectronically Stabilised Path, 16emergency stop, 17enabling device, 17equipment

mounting, 30permitted extra load, 30

extra equipmentconnections, 47

FFloor cables, 52

Manipulator, 52Manipulator, cable length, 52Manipulator, cable length-position switches axis 1,

53Manipulator, connection of Parallel communica-

tion, 52forklift, 44

Hhold-to-run control, 17humidity, 19

Iinstallation, 18Installation kit, 54

Internal Safety Concept, 17inverted robot, 18

Llimitation, 16load, 18, 20

Mmaintenance, 37manipulator colors, 45mechanical interface, 33motion, 38mounting

extra equipment, 30robot, 20

mounting flange, 33moveable, mechanical, main axes, 16

Nnoise level, 10

Ooperating requirements, 19option Absolute Accuracy, 35options, 45

PPassive Safety System, 16payload, 18performance, 42Positioner

Positioner cable 1, 53Positioner cable 2, 53Positioner cable type, 53Return cable, 53Weld return cable, 53

Positioners, 51positioning accuracy, 36Process, 54Process equipment, 55

Current/Hose set, 55Feed kit, 55Power source, 55Sensors, 56Torch service, 55

Process module, 54protection

foundry, 46standard, 46

protection standards, 19

Rrange of movement

working space, 38reduced speed, 17references, 34repeatability, 42

3HAC9112-1 Rev.Q 61

Index

Robot Peripherals, 59robot versions, 10

Ssafeguarded space stop, 17

delayed, 17safety, 14Safety category 3, 17Safety lamp, 49safety lamp, 17Self Tuning Performance, 16Service

ABB Torch cleaner, 55ABB Torch Service Center, 55

service, 37Service Information System, 15service information system, 15signal connections, 47space requirements, 10standards, 14structure, 7suspended robot, 18

Ttemperature, 19Track Motion, 51

type, 51Track motion RTT

Example of ordering, 51Travel length

additional, 51troubleshooting, 37

VVariants, 45variants, 45

Wweight, 10Working range limit

Axis 1, 50axis 2, 50axis 3, 51

working spacerestricting, 16, 18

62 Rev.Q 3HAC9112-1

ABB ABRobotics ProductsS-721 68 VÄSTERÅSSWEDENTelephone: +46 (0) 21 344000Telefax: +46 (0) 21 132592

3HA

C91

12-1

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3HAC9112-1_revQ_en

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