ABB Robotics IRB 1100 Product Manual Download Page 110

Page: 110 / 616

5.3.1 Replacing the upper cable package

Location of the upper cable package

The upper cable package is located as shown in the figure.

xx1800002466

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The spare part numbers that are listed in the table can be out of date.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 1100 via myABB Business Portal,

www.mypo-

rtal.abb.com

Note

Article number

Spare part

3HAC075521-001

Lower cable harness, basic

3HAC075522-001

Lower cable harness (CP/CS and
air hose, without Ethernet)

3HAC075523-001

Lower cable harness (CP/CS and
air hose, with Ethernet)

Used with IRB 1100-4/0.58.

3HAC060416-001

Extension upper cable harness,
basic

Used with IRB 1100-4/0.58.

3HAC060416-002

Extension upper cable harness
(CP/CS and air hose, without Ether-
net)

Used with IRB 1100-4/0.58.

3HAC060416-003

Extension upper cable harness
(CP/CS and air hose, with Ethernet)

Continues on next page

110

Product manual - IRB 1100

3HAC064992-001 Revision: C

5 Repair

5.3.1 Replacing the upper cable package

Summary of Contents for IRB 1100

Page 1: ...ROBOTICS Product manual IRB 1100 ...

Page 2: ...Trace back information Workspace 20B version a15 Checked in 2020 06 01 Skribenta version 5 3 033 ...

Page 3: ...Product manual IRB 1100 4 0 475 IRB 1100 4 0 58 OmniCore Document ID 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...nty by ABB for losses damage to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained ...

Page 5: ...3 2 Unpacking 48 3 2 1 Transportation bracket 3HAC068893 001 50 3 2 2 Pre installation procedure 51 3 2 3 Risk of tipping stability 53 3 3 On site installation 53 3 3 1 Lifting the robot 53 3 3 1 1 Lifting the robot by one person 55 3 3 1 2 Lifting and rotating a suspended mounted robot 56 3 3 2 Manually releasing the brakes 58 3 3 3 Orienting and securing the robot 60 3 3 4 Setting the system par...

Page 6: ...er arm 279 5 5 1 Replacing the lower arm 310 5 6 Housing extender unit and wrist 310 5 6 1 Replacing the housing 352 5 6 2 Replacing the extender unit and wrist 390 5 7 Motors 390 5 7 1 Replacing the axis 1 motor 405 5 7 2 Replacing the axis 2 motor 417 5 7 3 Replacing the axis 3 motor 428 5 7 4 Replacing the axis 4 motor 439 5 7 5 Replacing the axis 5 motor 449 5 7 6 Replacing the axis 6 motor 45...

Page 7: ...hanical noise or dissonance 594 7 4 Manipulator collapses on power down 595 8 Decommissioning 595 8 1 Introduction 596 8 2 Environmental information 598 8 3 Scrapping of robot 599 9 Reference information 599 9 1 Introduction 600 9 2 Applicable standards 602 9 3 Unit conversion 603 9 4 Screw joints 606 9 5 Weight specifications 607 9 6 Standard toolkit 608 9 7 Special tools 609 10 Spare parts 609 1...

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Page 9: ...ion craftsman working with an ABB robot must be trained by ABB and have the required knowledge of mechanical and electrical installation repair maintenance work be trained to respond to emergencies or abnormal situations Product manual scope The manual covers all variants and designs of the IRB 1100 Some variants and designs may have been removed from the business offer and are no longer available...

Page 10: ...r arm the lower arm to housing the housing to extender unit and the housing to wrist Added information of resonance sounds in troubleshooting for mechanical noise or dissonance Clarified text about position of robot and added table with depend encies between axes during Axis Calibration Clarified and added information in mounting instructions for rotat ing sealings see Mounting instructions for se...

Page 11: ...sioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application...

Page 12: ...ts The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 12 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved Product documentation Continued ...

Page 13: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 15 Illustrations The product is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several product models can be illustrated with illustrations that show a different...

Page 14: ...This page is intentionally left blank ...

Page 15: ...ration of the robot when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplie...

Page 16: ...ence of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot 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 product manual 16 Product manual IRB 1100 3HAC064992 001 Revisi...

Page 17: ...ion which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous...

Page 18: ...ed to indicate where to find additional information or how to do an operation in an easier way TIP 18 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 19: ...ription Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc Caution xx090000...

Page 20: ...0815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 20 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 2 2 Safety ...

Page 21: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 1100 21 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 22: ...1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 22 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 23: ...01242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 1100 23 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...at this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 24 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 25: ...d emergency stops are described in the product manual for the controller For more information see Product manual OmniCore C30 Product manual OmniCore C90XT Product manual IRB 1100 25 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 26: ...ot if dropped or released at maximum speed The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Conside...

Page 27: ...st ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards Other hazards WARNING Never stay beneath a robot arm Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNI...

Page 28: ...e release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 28 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 5 1 Unexpected movement of robot arm ...

Page 29: ...lubricants oil or grease When handling oil grease or other chemical substances the safety information of the respective manufacturer must be observed Note Take special care when handling hot lubricants Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling ...

Page 30: ...conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside There is a hazard in case of abuse mechanical thermal electrical which leads to the activation of safety valves and or the rupture of the battery container As a result under certain circumstances electrolyte leakage electrode materials reaction with moisture water or battery vent ex...

Page 31: ...se serious injuries on users and may damage equipment Related information See also the safety information related to installation and operation Product manual IRB 1100 31 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 6 1 Maintenance and repair Continued ...

Page 32: ...ire using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the manipulator does not result in additional hazards for example even more severe injuries on a trapped person DANGER 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 32...

Page 33: ...as described below 1 Run each axis to a position where the combined weight of the manipulator and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the manipulator does not change position as the motors are switched off then the brake function is adequate Product manual IRB 1100 33 3HAC064992 001 Revision C C...

Page 34: ...d engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Never stay beneath a robot arm Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety informatio...

Page 35: ...rm Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 1100 35 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 1 Safety 1 8 Decommissioning ...

Page 36: ...This page is intentionally left blank ...

Page 37: ...he directions of the robots stress forces The directions are valid for all floor mounted suspended and inverted robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz Continues on next page Product manual IRB 1100 37 3HAC064992 001 Revision C Copyright 20192020 ABB...

Page 38: ... Torque xy 140 Nm 90 Nm Torque z Wall mounted Max load emergency stop Endurance load in operation Force 210 660 N 210 370 N Force xy 540 Nm 370 N Force z 370Nm 200 Nm Torque xy 140 Nm 90 Nm Torque z Suspended Max load emergency stop Endurance load in operation Force 710 N 420 N Force xy 210 510 N 210 380 N Force z 330 Nm 180 Nm Torque xy 140 Nm 90 Nm Torque z Table mounted Maximum load emergency s...

Page 39: ...ss of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot movement even if the frequency is well below the stated frequency The robot should be mounted as rigid as possibly to the floor Disturbances from other machi...

Page 40: ...uns with lower performance due to temperature dependent oil and grease viscosity Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP40 Manipulator protection type Standard 40 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 2 Technical data 2 1 Te...

Page 41: ...14 562 A 182 101 17 135 135 158 C B xx1800002606 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C Continues on next page Product manual IRB 1100 41 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 2 Technical data 2 2 Dimensions ...

Page 42: ...617 A 101 182 17 135 135 158 C B xx1800002607 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C 42 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 2 Technical data 2 2 Dimensions Continued ...

Page 43: ...t wrist center and angle of axes 2 and 3 Angle degrees Positions at wrist center mm Position in the figure axis 3 axis 2 Z X 0 0 562 314 pos0 87 7 0 802 0 pos1 55 9 7 327 53 8 pos2 87 7 90 327 475 pos3 87 7 113 141 3 437 4 pos4 205 26 4 327 248 2 pos5 55 115 453 4 87 6 pos6 87 7 90 327 475 pos7 87 7 115 126 2 430 7 pos8 205 113 488 6 188 4 pos9 Continues on next page Product manual IRB 1100 43 3HA...

Page 44: ...ist center and angle of axes 2 and 3 Angle degrees Positions at wrist center mm Position in the figure axis 3 axis 2 Z X 0 0 617 364 pos0 88 0 907 2 0 pos1 55 12 5 327 184 6 pos2 88 90 327 580 pos3 88 113 100 3 534 pos4 205 28 3 327 304 pos5 55 115 473 5 112 4 pos6 88 90 327 580 pos7 88 115 81 8 525 8 pos8 205 113 517 1 237 3 pos9 Continues on next page 44 Product manual IRB 1100 3HAC064992 001 Re...

Page 45: ... other axes and that simulation in RobotStu dio is recommended to find out what is pos sible 230 Axis 1 115 113 Axis 2 Value for restricted working range 205 55 Axis 3 Default value 230 Axis 4 125 120 Axis 5 Default value 400 Axis 6 Maximum revolution value 242 The default working range for axis 6 can be extended by changing parameter values in the software Product manual IRB 1100 45 3HAC064992 00...

Page 46: ...e Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual OmniCore C30 Product manual OmniCore C90XT Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static ...

Page 47: ...t that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page15 before performing any installation work Note If the IRB 1100 is connected to power always make sure that the robot is connected to protective earth...

Page 48: ...e work and must be refitted before shipping and transportation IRB 1100 4 0 58 IRB 1100 4 0 475 xx1800002442 xx1800002441 Removing the transportation bracket Note Action xx1900000105 If there are screws fixed to the pallet or foundation in the location shown in the figure remove the screws and nuts 1 Continues on next page 48 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB...

Page 49: ... and washers 2 xx1900000103 xx1900000104 Remove the bracket 3 Product manual IRB 1100 49 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 2 1 Transportation bracket 3HAC068893 001 Continued ...

Page 50: ...red is suitable to handle the weight of the robot as specified in Weight robot on page 37 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 39 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 39 7 Before taking the robot to its installation si...

Page 51: ...e shipping position is the most stable position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position IRB 1100 4 0 475 41 4 16 5 xx1900000106 Continues on next page Product manual IRB 1100 51 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Ins...

Page 52: ...t be removed before conducting any service work How to use the transportation bracket is described further in Transportation bracket 3HAC068893 001 on page 48 WARNING The robot is likely to be mechanically unstable if not secured to the foundation 52 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 2 3 Risk of tipping s...

Page 53: ...4 Stand on foot When the robot lies by side grasp the ro bot with one hand holding the lower arm and the other hand supporting at the base It is recommended to hold the robot between your arm and body xx1800002445 By side When the robot is inverted grasp the robot with one hand supporting at the housing and the other hand holding the base xx1800002446 Invented Continues on next page Product manual...

Page 54: ...ired position CAUTION Be careful so that the robot does not bump into something while lifting and transporting It could damage the robot 4 Secure the robot on a workbench according to section Orienting and securing the robot on page 58 5 54 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 3 1 1 Lifting the robot by one ...

Page 55: ...ition Contact ABB for more information How to lift and turn the robot into position for wall position Contact ABB for more information Product manual IRB 1100 55 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 3 1 2 Lifting and rotating a suspended mounted robot ...

Page 56: ...ped with a brake release unit Note Action Note If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 57 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpec ted ways Make sure no personnel is near or beneath the ro bot 2 Continues on next p...

Page 57: ...able the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously and instantly 1 xx1800002443 Supply 0V on pin 12 24V on pin 11 Note Do not interchange the 24v and 0V pins If they are mixed up damage can be caused to the brake release unit and to the system board 2 Use the brake releasing button as d...

Page 58: ... secure the robot Note Action Make sure the installation site for the robot con forms to the specifications in section Technical data on page 37 1 The hole configuration of the base is shown in the figure in Hole con figuration base on page 59 Prepare the installation site with attachment holes 2 CAUTION The weight of the IRB 1100 robot is 21 1 kg All lifting accessories used must be sized accord ...

Page 59: ...e 50 Nm 5 Nm Tighten the bolts in a crosswise pattern to ensure that the base is not distorted 9 Hole configuration base This illustration shows the hole configuration used when securing the robot 4x M12 11 11 10 4 135 135 6 H7 0 012 0 5 5 11 5 11 5 5 5 6 H7 0 012 0 4x R16 135 135 11 11 10 4 R16 11 5 5 5 6 A A 10 A A 4x M12 11 11 10 4 135 135 6 H7 0 012 0 5 5 11 5 11 5 5 5 6 H7 0 012 0 4x R16 xx18...

Page 60: ...rol the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection Gravity Beta When the robot is mounted other than floor standing rotated around the y axis the robot base frame and the syst...

Page 61: ...n Gamma Rotation defines the orientation of the robot foot on the travel carriage track motion Mounting angles and values The parameter Gravity Beta or Gravity Alpha specifies the mounting angle of the robot in radians It is calculated in the following way Gravity Beta A x 3 141593 180 B radians where A is the mounting angle in degrees and B is the mounting angle in radians Gravity Beta Mounting a...

Page 62: ...e 45 Tilted Pos 2 Mounting angle 90 Wall Pos 3 Mounting angle 180 Suspended Pos 4 Continues on next page 62 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 3 4 Setting the system parameters for a suspended or a tilted robot Continued ...

Page 63: ... 0 0 Floor mounted 1 0 785398 45 Tilted 2 1 570796 90 Wall 3 1 570796 90 Wall 4 Note For suspended robots 180 it is recommended to use Gravity Beta instead of Gravity Alpha Continues on next page Product manual IRB 1100 63 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 3 4 Setting the system parameters for a suspended or a tilted robot Conti...

Page 64: ...nting angle must be redefined when changing the mounting angle of the robot The parameters belong to the type Robot in the topic Motion The system parameters are described in Technical reference manual System parameters The system parameters are configured in RobotStudio or on the FlexPendant 64 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installa...

Page 65: ...ed loads may result in operational stops or major damage to the robot Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot Product manual IRB 1100 65 3HAC064992 001 Revision C...

Page 66: ... connector on the controller Note The local I O connectors provides 16 digital output signals for use 2 Configure the lamp by adding a System Output type signal with status set to Motors On State 3 The lamp is now ready for use and is lit in MOTORS ON mode 4 Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller Further inf...

Page 67: ...4 0 475 173 609 327 225 10 250 64 314 562 A 182 101 17 135 135 158 C B xx1800002606 Description Pos Turning radius R85 A Turning radius R109 B Continues on next page Product manual IRB 1100 67 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions ...

Page 68: ...4 617 A 101 182 17 135 135 158 C B xx1800002607 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C Continues on next page 68 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 69: ...ds on center of gravity of arm load and robot payload Holes for fitting extra equipment B C D 16 4x M3 x6 40 4x M5x10 4x M4x6 40 B C D 169 A 145 B xx1800002449 IRB 1100 4 0 58 IRB 1100 4 0 475 Pos 303 248 A 250 200 B Continues on next page Product manual IRB 1100 69 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the ...

Page 70: ... 8 G 426 E F xx1800002450 Continues on next page 70 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 3 7 Fitting equipment on the robot robot dimensions Continued ...

Page 71: ...e mark has been made to the tool at the corresponding position For details about the synchronization mark see Synchronization marks and synchronization position for axes on page 563 Fastener quality Use suitable screws and tightening torque for your application screws with quality class 12 9 are recommended Product manual IRB 1100 71 3HAC064992 001 Revision C Copyright 20192020 ABB All rights rese...

Page 72: ...t may collide with other objects its working space should be limited The working range of the following axes may be restricted Software restriction Mechanical restric tion Axis x x Axis 1 x Axis 2 x Axis 3 x Axis 4 x Axis 5 x Axis 6 72 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 4 1 Axes with restricted working ran...

Page 73: ...the IRB 1100 via myABB Business Portal www mypo rtal abb com Note Article number Spare part Replace if damaged 3HAC061947 001 Mechanical stop axis 1 Replacement of the axis 1 mechanical stop The axis 1 mechanical stop is accessible after removing the base see Replacing the base on page 194 Product manual IRB 1100 73 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installatio...

Page 74: ... databus communication The customer cables also include the air hose See the product manual for the controller see document number in References on page 9 The hose for compressed air is integrated with the manipu lator cable harness Air hoses Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connection p...

Page 75: ... cables A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1800002453 Continues on next page Product manual IRB 1100 75 3HAC064992 001 Revision C Copyright 20192020 ABB All rights ...

Page 76: ...9 003 15 m Customer cables Ethernet floor cable option Article number Ethernet floor cable length 3HAC067447 002 7 m 3HAC067447 003 15 m 76 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 5 1 Robot cabling and connection points Continued ...

Page 77: ...ose for compressed air is also integrated into the manipulator There are 4 inlets at the base R1 8 and 4 outlets M5 on the wrist A B C A B C C xx1900000131 Value Number Description Connection Position 30 V 1 5 A 8 wiresi Customer power signal R1 R2 C1 A 30 V 1 A or 1 Gbits s 8 wires Customer power signal or Ethernet R1 R2 C2 B Inner hose diameter 4 mm 4 Max 6 bar Air C i The connector has 12 pins ...

Page 78: ...ctor kits Protection covers Protection covers for water and dust proofing Protection covers are delivered together with the robot and must be well fitted to the connectors in any application requiring water and dust proofing Always remember to refit the protection covers after removing them A C C B xx1900000132 CP CS or Ethernet connector protection covers A SMB connector protection cover B Air ho...

Page 79: ...r the speed regulator on the FlexPendent Start the robot with its normal program but with reduced speed Note It is recommended to reduce the speed to a value smaller than 40 of the normal pro grammed speed 1 The warm up duration varies according to the working cycle If the working cycle is not tough enough a longer warm up duration is required After 10 minutes or more run the robot with the normal...

Page 80: ...ntation velocity which is always high in predefined velocities needs to be included in the ramping up 80 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 3 Installation and commissioning 3 6 Start of robot in cold environments Continued ...

Page 81: ...he maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 15 before performing any service work Note If the IRB 1100 is connected to power a...

Page 82: ...unning means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS used in OmniCore is further described in the Operating manual OmniCore Robots with the functionality Service Information System activated can show active counters in t...

Page 83: ...age 95 x v Lubricating the robot harness x Overhaul of complete robot Replacing the battery pack on page 97 x vi Replacing the SMB battery pack i Regularly implies that the activity is to be performed regularly but the actual interval may not be specified by the robot manufacturer The interval depends on the operation cycle of the robot its working environment and movement pattern Generally the mo...

Page 84: ...ge in regard to movement most material handling applications and limited use of bending backwards mode of axis 3 ii Severe chemical or thermal environments or similar environments can result in shortened life expectancy iii 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 84 ...

Page 85: ... robot before cleaning Do not point the water jet at connectors joints sealings or gaskets Do not use compressed air to clean the robot Do not use solvents that are not approved by ABB to clean the robot Do not spray from a distance closer than 0 4 m Do not remove any covers or other protective devices before cleaning the robot Cleaning methods These following table defines what cleaning methods a...

Page 86: ...ad Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Cables Movable cables need to be able to move freely 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 1 See Cleaning methods on page 85 for exceptions 86 Produc...

Page 87: ... label ABB logo Rating label Calibration label WEEE A A B A C D E F xx1800003316 ABB logo A Instruction label B Brake release UL label C Read manual label also specifying warning labels D Rating label CE label and AbsAcc label E Calibration label F Required tools and equipment Visual inspection no tools are required Continues on next page Product manual IRB 1100 87 3HAC064992 001 Revision C Copyri...

Page 88: ...feguarded space 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare parts on page 609 Replace any missing or damaged labels 3 88 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 4 Maintenance 4 4 1 Inspecting the information labels Continued ...

Page 89: ...en necessary Required tools and equipment Visual inspection no tools are required Inspecting for oil seepage Check the points of oil seepage especially the seal lips and cover edges of the robot regularly If oil accumulation is observed wipe it clean softly with a lint free cloth to prevent oil dropping Product manual IRB 1100 89 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved...

Page 90: ...robot cabling Use this procedure to inspect the robot cabling Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Visually inspect the control cabling between the robot and control cabinet Look for abrasions cuts or crush damage 2 Replace the cabling if wear or damage is ...

Page 91: ...axis 4 timing belts when replacing the motors The timing belts are located as shown in the figures Location Axis xx1800002457 1 xx1800002458 2 Continues on next page Product manual IRB 1100 91 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 4 Maintenance 4 4 4 Inspecting timing belts ...

Page 92: ...n Axis xx1800002459 3 xx1800002460 4 Continues on next page 92 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 4 Maintenance 4 4 4 Inspecting timing belts Continued ...

Page 93: ...oolkit on page 607 Standard toolkit Other tools and procedures may be required if the spare part needs to be replaced These are specified in the replacement procedure Continues on next page Product manual IRB 1100 93 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 4 Maintenance 4 4 4 Inspecting timing belts Continued ...

Page 94: ...or more than 12 hours but less than 150 hours When the timing belt has been installed and used for more than 150 hours both the force and frequency values decrease 30 ii The value range is only for reference Inspecting timing belts Use this procedure to inspect timing belts Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot befor...

Page 95: ...andard toolkit Other tools and procedures may be required if the spare part needs to be replaced These are specified in the replacement procedure Required consumables Note Article number Consumable FM 222 3HAC029132 001 Grease Lubricating the cable package Use this procedure to lubricate the cable package Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pr...

Page 96: ... cable package on page 152 If any damage or wear is detected the part must be replaced 4 Apply grease to the cable package cover all moving area of the package 5 Apply grease to the covers that have con tacting area with the cable package 6 96 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 4 Maintenance 4 5 1 Lubricating the cable package Continued ...

Page 97: ...be out of date See the latest spare parts of the IRB 1100 via myABB Business Portal www mypo rtal abb com Note Article number Spare part Battery includes protection cir cuits Only replace with the spe cified spare part or an ABB ap proved equivalent 3HAC044075 001 Battery pack Continues on next page Product manual IRB 1100 97 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 4 M...

Page 98: ...n method as used at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Removing the battery pack Use these procedures to remove the ...

Page 99: ...ove the SMB cover attachment screws and carefully open the cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures CAUTION There are cabling attached to the cover The cover cannot be removed completely until the connectors are removed 3 xx1800002468 Disconnect the connectors SMB P7 SMB J1 SMB J2 Tip Take ph...

Page 100: ...RGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 2 xx1800002469 Disconnect the battery cable 3 xx1800002470 Remove the battery pack by cutting the cable strap 4 Continues on next page 100 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 4 Maintenance 4 6 1 Replaci...

Page 101: ...800002470 Secure the battery pack using the cable strap 2 xx1800002469 Reconnect the battery cable 3 Reconnecting the SMB cabling Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 1 Continues on next page Product manual IRB 1100 101 3HAC064992 001 Revision C Copyright 20192020...

Page 102: ...cured incorrectly the cables can be damaged 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 6 pcs Refit the SMB cover to the base 4 Tightening torque 1 2 Nm xx1800002467 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 102 Product manual IRB 1100 3HAC064...

Page 103: ...cement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 15 before commencing any service work Note The robot should be secured with the transportation brackets during removing from refitting to the foundation Note If the IRB 1100 is connected to power always make sur...

Page 104: ...The pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that n...

Page 105: ... well before actual mounting The fitting of sealings and gears must be carried out on clean workbenches Use a protective sleeve for the main lip during mounting when sliding over threads keyways or other sharp edges Note Action Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches or damage ar...

Page 106: ...e space between the dust lip and the main lip with grease If the sealing is without dust lip just lubricate the main lip with a thin layer of grease 3 A xx2000000072 A Gap Mount the sealing correctly with a mounting tool Never hammer directly on the sealing as this may result in leakage 4 Continues on next page 106 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights...

Page 107: ...n the screws evenly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Check the o ring grooves 3 The grooves must be geometrically correct and should ...

Page 108: ...t Knife Lint free cloth Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 108 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 2 3 Cut the pa...

Page 109: ...ng and then into the wrist The main cable package includes the cabling for all the six motors Optional air hoses CP CS cabling and Ethernet cabling can also be included As standard feature the connector interface is located at the rear of the base The interface can also be bottom mounted as an option This section describes both configurations Continues on next page Product manual IRB 1100 109 3HAC...

Page 110: ...basic 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet Used with IRB 1100 4 0 58 3HAC060416 001 Extension upper cable harness basic Used with IRB 1100 4 0 58 3HAC060416 002 Extension upper cable harness CP CS and air hose without Ether net Used with IRB 1100 4 0 58 3HAC060416 003 Extension upper cable harness...

Page 111: ... pad for axis 1 and 2 mo tors Cooling pads are wear parts One cooling pad sheet includes 10 pieces of small pad Replace if damaged with one piece each time 3HAC071021 001 Cooling pad for axis 3 and 4 mo tors 9x4 3x1 Steel 3HAC063985 001 Washer 7x3 2x1 5 Steel 3HAC064765 001 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 607 ...

Page 112: ...tools to be removed from the mounting flange also for reference calibration since the mount ing flange is used for installation of the calibration tool Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from t...

Page 113: ... 1100 4 0 475 6 IRB 1100 4 0 58 Axis 4 0 Axis 5 0 Axis 6 No significance 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 3 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002488 Remove the swing support...

Page 114: ...he connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 5 xx1800002492 Remove the swing cover 6 Continues on next page 114 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repa...

Page 115: ... lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 10 Continues on next page Pr...

Page 116: ...800002497 Disconnect the connectors J2 FB3 4 5 6 J2 MP3 4 5 6 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 2 xx1800002498 Snap loose and remove the female head of the connectors from the connector plate 3 Continues on next page 116 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5...

Page 117: ...ir hoses CP CS cabling and Ethernet cabling if equipped Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002500 Disconnect the air hoses from the Y shaped con nectors 2 Continues on next page Product manual IRB 1100 117 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the uppe...

Page 118: ... Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002944 Remove the screws and carefully open the cover CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors are disconnected as shown in following steps 2 Continues on next page 118 Product manual IRB 11...

Page 119: ... con nector J5 UL 4 xx1800002947 For robots with CP CS cabling Disconnect the connector J5 C1 5 J5 C2 connector assembly tool xx1800002948 For robots with Ethernet cabling Disconnect the connector J5 C2 using the tool 6 Continues on next page Product manual IRB 1100 119 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 120: ...the axis 5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002950 Access the connector FB5 from the process hub and disconnect the connector 2 Continues on next page 120 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable ...

Page 121: ...ssure are turned off 1 xx1800002994 Disconnect the connectors MP6 FB6 2 Removing the axis 6 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 121 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 122: ...e the timing belt from its groove on the motor 5 Loosening the cable package from axis 4 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 122 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 123: ...ess the cable package locking screw on the axis 4 gearbox and then loosen the locking screw 3 xx1800003001 Separating the upper cable harness from the axis 2 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 123 3HAC064992 001 Revision C Copyright 20192020 ABB All rights re...

Page 124: ...wer arm support cover 2 xx1800003004 Remove the connector plate CAUTION Be aware of the cablings that are attached to the connector plate The connector plate cannot be removed completely until the connectors are re move from the plate as shown in following step 3 Continues on next page 124 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 R...

Page 125: ...connecting 4 xx1800003006 Remove the cable bracket 5 Removing the axis 3 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003007 Remove the lower arm cover 2 Continues on next page Product manual IRB 1100 125 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cab...

Page 126: ...he motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 5 Continues on next page 126 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continue...

Page 127: ...l supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003011 Remove the housing cover 2 xx1800003012 Disconnect the motor connectors FB4 MP4 3 Continues on next page Product manual IRB 1100 127 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 128: ...03013 Remove the cable bracket 2 xx1800003014 Pulling out the upper cable harness Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 128 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 129: ...cable harness from the robot in the direction shown in the figure 2 Continues on next page Product manual IRB 1100 129 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 130: ...ich should be at the opposite direction to the locking screw hole B on the gearbox xx1800003017 Insert the cable package in the housing and through the axis 4 gearbox Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 1 xx1800003601 Continues on next page 130 Product manual IRB 1100 3HAC064992 001 Revision C Copyrigh...

Page 131: ...ew hole on the gearbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 1 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page Product manual IRB 1100 131 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cab...

Page 132: ... residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for IRB 1100 4 0 58 xx1800003001 Plug screw 3HAC064146 001 Valid for IRB 1100 4 0 58 3 Tightening torque 2 Nm xx1800003000 Refit the plug screw and washer on the extender unit Continues on next page 132 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB A...

Page 133: ... motor connectors in the lower arm Tip Wrap the connectors with the masking tape Tip It is possible to remove the lower arm support and swing support for easy routing of the cable pack age Remember to refit the lower arm support and swing support after the cable package is inserted to place 1 Continues on next page Product manual IRB 1100 133 3HAC064992 001 Revision C Copyright 20192020 ABB All ri...

Page 134: ...met 500 2 pcs Tightening torque 0 6 Nm xx1800003014 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 2 Continues on next page 134 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Conti...

Page 135: ... find the corresponding connector 2 Refitting the axis 3 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Cooling pad for axis 3 and 4 mo tors 3HAC071021 001 xx1800003604 Check the cooling pad Replace if damaged 2 Continues on next page Product manual IRB 1100 135 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved...

Page 136: ...omet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 4 Washer 3HAC063985 001 3 pcs xx1800003009 xx1800003022 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 5 Continues on next page 136 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the uppe...

Page 137: ...3 94 N for reference only Use a handheld tensiometer hooking to the screw and pull the tensiometer to reach the initial refer enced force 7 Initial referenced force for new belt 31 34 2 N xx1900000028 Continues on next page Product manual IRB 1100 137 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 138: ...nd readjust 10 xx1900000009 Remove the adjustment screw from the motor 11 Reconnecting the axis 3 motor connectors Note Action xx1800003005 Slide the connectors into the connector plate and reconnect the connectors FB3 MP3 Tip See the number markings on the connectors for help to find the corresponding connector 1 Continues on next page 138 Product manual IRB 1100 3HAC064992 001 Revision C Copyrig...

Page 139: ...2 5x6 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Screw M3x12 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the connector plate 4 Tightening torque 0 4 Nm xx1800003004 Continues on next page Product manual IRB 1100 139 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 140: ...nd undamaged 1 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003023 Orient the motor correctly and fit it into the lower arm Tip Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side 2 Continues on next page 140 Product manual IRB 1100 3HAC064992 001 Revision C ...

Page 141: ...r adjustment screw to the motor Note Do not insert the entire screw to the hole 5 Initial referenced force for used belt 8 96 9 8 N for reference only Use a handheld tensiometer hooking to the screw and pull the tensiometer to reach the initial refer enced force 6 Initial referenced force for new belt 12 8 14 xx1900000026 Continues on next page Product manual IRB 1100 141 3HAC064992 001 Revision C...

Page 142: ...t loosen the motor screws and readjust 9 xx1900000007 Remove the adjustment screw from the motor 10 Reconnecting the axis 5 motor connectors Note Action xx1800003025 Reconnect the connectors FB5 MP5 Tip See the number markings on the connectors for help to find the corresponding connector 1 Continues on next page 142 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All righ...

Page 143: ...rresponding connector 1 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 2 Insert the cabling and connectors into the wrist 3 Refitting the process hub Note Action xx1800002946 For robots with safety lamp option 3308 1 Reconnect the connector J5 UL and place the connector behi...

Page 144: ...connector assembly tool in cluded in the special toolkit 3HAC071022 001 xx1800002948 For robots with Ethernet cabling Reconnect the connector J5 C2 using the tool 4 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 5 Continues on next page 144 Product manual IRB 1100 3HAC064992...

Page 145: ...p See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y shaped connector 1 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page Product manual IRB 1100 145 3HAC064992 001 Revision C Copyright 201920...

Page 146: ...hat all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 2 Continues on next page 146 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package C...

Page 147: ...on nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 Screw M4x16 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page Product manual IRB 1100 147 3HAC064992 001 Revision C Copyright 20192020 ABB All ri...

Page 148: ... to the hole 7 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld tensiometer hooking to the screw and pull the tensiometer to reach the initial refer enced force 8 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page 148 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 ...

Page 149: ...oes not meet the require ment loosen the motor screws and readjust 11 xx1900000010 Remove the adjustment screw from the motor 12 xx1800002495 Reconnect the connector MP2 Tip See the number markings on the connectors for help to find the corresponding connector 13 Continues on next page Product manual IRB 1100 149 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 1 R...

Page 150: ...ponding connector 2 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 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Continues on next page 150 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020...

Page 151: ...Lower arm cover Lower arm support cover Swing cover Swing support cover 3 Tightening torque 1 2 Nm xx1800003606 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 1100 151 3HAC064992 001 Revision C Copyright 20192020 ABB All right...

Page 152: ...r cable harness basic 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet 3HAC066144 001 Motor with flange axis 2 3HAC061935 001 Timing belt axis 2 Standard configuration used for robots with rear connector inter face 3HAC060463 001 Base bottom cover Used for robots with bottom con nector interface 3HAC070312 00...

Page 153: ...ation tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for measuring the timing belt tension Acoustic tensiometer Used for measuring the timing belt tension Tensiometer Included in the special toolkit 3HAC071022 001 Used to remove and refit the brake release button brake release button assembly tool i The robot is calibrated by either manual calibration or Axis ...

Page 154: ...Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 570 If no previous reference values exist and no new reference val...

Page 155: ...d air pressure are turned off 1 xx1800002488 Remove the swing support cover 2 xx1800002489 Remove the connector plate CAUTION Be aware of the cablings that are attached to the connector plate The connector plate cannot be removed completely until the connectors are re move from the plate 3 Continues on next page Product manual IRB 1100 155 3HAC064992 001 Revision C Copyright 20192020 ABB All right...

Page 156: ...ead of the connector from the connector plate 5 xx1800002492 Remove the swing cover 6 xx1800002495 Disconnect the connector MP2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 7 Continues on next page 156 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lo...

Page 157: ...ic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 10 xx1800002496 Remove the timing belt from its groove on the motor 11 Continues on next page Product manual IRB 1100 157 3HAC064992 001 Revisio...

Page 158: ...ecting the connectors at the division point Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002497 Disconnect the connectors J2 FB3 4 5 6 J2 MP3 4 5 6 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 2 Continues on next page 158 Product manual IRB 110...

Page 159: ...air pressure are turned off 1 xx1800002499 Remove the cable bracket 2 Disconnecting the air hoses CP CS cabling and Ethernet cabling if equipped Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 159 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2...

Page 160: ... Tip The connector clip has to be pressed 1 and pushed forward 2 to separate the J2 C2 for Ethernet cabling xx1800002943 3 Disconnecting the SMB cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 160 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repa...

Page 161: ...mpletely until the connectors are removed 3 xx1800002468 Disconnect the connectors SMB P7 SMB J1 SMB J2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Remove the SMB cover completely from the base 5 Putting the robot on its side Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pr...

Page 162: ...achment screws and put the robot on its side 4 Opening the connector interface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 162 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 163: ...emoved completely until the connectors are removed 2 xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 xx1800003056 Valid for cabling with bottom interface option 3309 1 Remove the base adapter 3 Continues on next page Product manual IRB 1100 163 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Cont...

Page 164: ...ic pressure and air pressure are turned off 1 xx1800003035 Valid for cabling with rear interface Remove the base bottom cover 2 xx1800003057 Valid for cabling with bottom interface option 3309 1 Remove the base rear cover 3 xx1800003036 Disconnect the earth cable 4 Continues on next page 164 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2...

Page 165: ...osition before disconnecting them to have as a reference when reconnecting 6 xx1800003039 Remove the female header of the J1M BR connect or from the connector plate 7 Continues on next page Product manual IRB 1100 165 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 166: ...ned off 1 xx1800003041 Disconnect the connectors FB1 MP1 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 2 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 166 Product manual IRB 1100 3HAC064...

Page 167: ...air pressure are turned off 1 xx1800003043 Remove the pulley cover 2 Pulling out the cable package Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 167 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 168: ...5 Pull out the lower cable package from the base 3 xx1800003046 Remove the pulley cover from the lower cable package 4 Continues on next page 168 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 169: ... not tighten the button yet 1 xx1800003040 Refitting the lower cable package through the axis 1 gearbox Notice that the procedure differs depending on if the connector interface is located either at the rear or at the bottom of the base Note Action xx1800003046 Refit the pulley cover to the lower cable package 1 Continues on next page Product manual IRB 1100 169 3HAC064992 001 Revision C Copyright...

Page 170: ...ted or strained Reroute if necessary 2 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page 170 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair ...

Page 171: ... are twisted or strained Reroute if necessary 3 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page Product manual IRB 1100 171 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved ...

Page 172: ...screw hole on the gearbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 1 xx1800003049 xx1800003050 Continues on next page 172 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 173: ...id after refitting Refitting the pulley cover Note Action Screw M3x8 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the puller cover 1 Tightening torque 1 2 Nm xx1800003043 Reconnecting the SMB cabling Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 1 Continues on next page Product...

Page 174: ...bles can be damaged 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 6 pcs Refit the SMB cover to the base 4 Tightening torque 1 2 Nm xx1800002467 Refitting the connector interface plate Note Action 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 1 Continues on next page 174 Product ...

Page 175: ...Geomet 500 6 pcs Refit the connector interface plate to the base 3 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page Product manual IRB 1100 175 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 176: ...Securing the brake release button Note Action brake release button assembly tool included in the special toolkit 3HAC071022 001 Tighten the brake release button using the tool 1 xx1800003040 Continues on next page 176 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 177: ...r help to find the corresponding connector 1 Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Reconnect the floor cable together with the con nector plate 2 Tightening torque 0 8 Nm xx1800003037 xx1800003036 Continues on next page Product manual IRB 1100 177 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 178: ...t cable routing is highly important If the cables are routed and secured incorrectly the cables can be damaged 3 Screw M3x8 Steel 8 8 A2F 7 pcs Valid for cabling with rear interface 4 Tightening torque 1 2 Nm Refit the bottom cover xx1800003035 Screw M3x8 12 9 Gleitmo 603 Geomet 500 6 pcs Valid for cabling with bottom interface option 3309 1 5 Tightening torque 1 2 Nm Refit the rear cover xx180000...

Page 179: ...ing and Ethernet cabling if equipped Note Action xx1800002500 Reconnect the air hoses in a cross pattern to the Y shaped connectors Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y shaped connector 1 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for he...

Page 180: ...hat all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 2 Continues on next page 180 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package C...

Page 181: ...on nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 Screw M4x16 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page Product manual IRB 1100 181 3HAC064992 001 Revision C Copyright 20192020 ABB All ri...

Page 182: ... to the hole 7 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld tensiometer hooking to the screw and pull the tensiometer to reach the initial refer enced force 8 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page 182 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 ...

Page 183: ...oes not meet the require ment loosen the motor screws and readjust 11 xx1900000010 Remove the adjustment screw from the motor 12 xx1800002495 Reconnect the connector MP2 Tip See the number markings on the connectors for help to find the corresponding connector 13 Continues on next page Product manual IRB 1100 183 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 R...

Page 184: ...ponding connector 2 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 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Continues on next page 184 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020...

Page 185: ...e covers Swing cover Swing support cover 3 Tightening torque 1 2 Nm xx1800003607 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 1100 185 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 2 Repla...

Page 186: ...B 1100 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC063968 001 Serial measurement unit 3HAC069060 001 SMB cover Battery includes protection cir cuits Only replace with the spe cified spare part or an ABB ap proved equivalent 3HAC044075 001 Battery pack Continues on next page 186 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All right...

Page 187: ...be required prior to beginning the repair work of the robot see the table Note Action Note Calibrating axis 6 always requires tools to be removed from the mounting flange also for reference calibration since the mount ing flange is used for installation of the calibration tool Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack ...

Page 188: ...beginning the repair procedure 1 xx1800003288 Jog all axes to zero position 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 3 Disconnecting the SMB cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 188 Pro...

Page 189: ...moved 3 xx1800002468 Disconnect the connectors SMB P7 SMB J1 SMB J2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Remove the SMB cover completely from the base 5 Removing the battery pack Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DI...

Page 190: ...ectrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 2 Continues on next page 190 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 3 Replacing the SMB unit Continued ...

Page 191: ...to ESD on page 46 1 Screw M3x5 12 9 Gleitmo 603 Geomet 500 4 pcs Refit the screws 2 Tightening torque 0 8 Nm xx1800002471 Refitting the battery pack Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 1 Continues on next page Product manual IRB 1100 191 3HAC064992 001 Revision C...

Page 192: ...he unit read the safety information in section The unit is sensitive to ESD on page 46 1 Tightening torque 0 3 Nm Reconnect the connectors 2 xx1800002468 SMB P7 SMB J1 SMB J2 Tip See the number markings on the connectors for help to find the corresponding connector Continues on next page 192 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 3...

Page 193: ... 6 pcs Refit the SMB cover to the base 4 Tightening torque 1 2 Nm xx1800002467 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 1100 193 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 3 3 Replaci...

Page 194: ...b com Note Article number Spare part 3HAC075521 001 Lower cable harness basic 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet 3HAC069048 001 Base 3HAC066143 001 Motor with flange axis 1 3HAC061934 001 Timing belt axis 1 3HAC066144 001 Motor with flange axis 2 Continues on next page 194 Product manual IRB 110...

Page 195: ...xis Calibration is the valid calibration method for the robot i The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for measuring the timing belt tension Acoustic tensiometer Used for measuring the timing belt tens...

Page 196: ...ion routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis ...

Page 197: ...e safeguarded space 3 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002488 Remove the swing support cover 2 Continues on next page Product manual IRB 1100 197 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 198: ...nnect the connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 5 xx1800002492 Remove the swing cover 6 Continues on next page 198 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved...

Page 199: ...refully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 10 Continues on next ...

Page 200: ...s the cable package locking screw on the axis 1 gearbox from the swing and then loosen the locking screw 2 Remove the locking screw 3 Disconnecting the connectors at the division point Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 200 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 2019202...

Page 201: ...ve the female head of the connectors from the connector plate 3 Separating the cable package from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002499 Remove the cable bracket 2 Continues on next page Product manual IRB 1100 201 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 ...

Page 202: ...ors 2 xx1800002501 Disconnect the connectors J2 C1 J2 C2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting Tip The connector clip has to be pressed 1 and pushed forward 2 to separate the J2 C2 for Ethernet cabling xx1800002943 3 Continues on next page 202 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB Al...

Page 203: ...ndation by removing the foundation attachment screws and put the robot on its side 4 Disconnecting the SMB cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 2 C...

Page 204: ...d 3 xx1800002468 Disconnect the connectors SMB P7 SMB J1 SMB J2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Remove the SMB cover completely from the base 5 Opening the connector interface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continue...

Page 205: ...not be removed completely until the connectors are removed 2 xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 xx1800003056 Valid for cabling with bottom interface option 3309 1 Remove the base adapter 3 Continues on next page Product manual IRB 1100 205 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 206: ...hydraulic pressure and air pressure are turned off 1 xx1800003035 Valid for cabling with rear interface Remove the base bottom cover 2 xx1800003057 Valid for cabling with bottom interface option 3309 1 Remove the base rear cover 3 xx1800003036 Disconnect the earth cable 4 Continues on next page 206 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repai...

Page 207: ...cable position before disconnecting them to have as a reference when reconnecting 6 xx1800003039 Remove the female header of the J1M BR connect or from the connector plate 7 Continues on next page Product manual IRB 1100 207 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 208: ... are turned off 1 xx1800003041 Disconnect the connectors FB1 MP1 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 2 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 208 Product manual IRB 1100...

Page 209: ...re and air pressure are turned off 1 xx1800003043 Remove the pulley cover 2 Pulling out the cable package Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 209 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 210: ...move the pulley cover from the lower cable package 4 Removing the axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 210 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 211: ...t out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 4 Continues on next page Product manual IRB 1100 211 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 212: ...ssure are turned off 1 xx1800003067 Remove the timing belt from its groove on the gearbox 2 Separating the base from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 212 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the bas...

Page 213: ...em to have as a reference when refitting xx1800003068 2 xx1800003070 Separate the base from the swing CAUTION The axis 1 mechanical stop is accessible now Put it aside for later refitting xx1800003071 3 Continues on next page Product manual IRB 1100 213 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 214: ...71 Put the axis 1 mechanical stop in place in the swing Note The mechanical stop can be placed in any place except the block A on the swing Make sure the mechanical stop step pointed in the figure is fa cing the swing when putting xx1800003619 2 Continues on next page 214 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base ...

Page 215: ... button assembly tool included in the special toolkit 3HAC071022 001 Refit the brake release button Note Do not reconnect the connector yet Do not tighten the button yet 1 xx1800003040 Refitting the axis 1 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Continues on next page Product manual IRB 1100 215 3HAC064992 001 Revision C C...

Page 216: ...tation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003072 Orient the motor correctly and fit it into the base At the same time install the timing belt to the gearbox pulley and verify that the belt runs cor rectly in the groove of the pulley 4 Continues on next page 216 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All...

Page 217: ... N Pull the tensiometer to make the tension falling in the allowed force range Note During the measurement make sure that all inter ferences that may affect the force are removed Pay attention to the force application direction 2 New belt 83 2 90 8 N for reference only xx1900000041 Tightening torque 3 Nm Secure the motor with the screws 3 Continues on next page Product manual IRB 1100 217 3HAC0649...

Page 218: ...able package through the axis 1 gearbox Notice that the procedure differs depending on if the connector interface is located either at the rear or at the bottom of the base Note Action xx1800003046 Refit the pulley cover to the lower cable package 1 Continues on next page 218 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the b...

Page 219: ...re twisted or strained Reroute if necessary 2 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page Product manual IRB 1100 219 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 ...

Page 220: ...r hoses are twisted or strained Reroute if necessary 3 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page 220 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights re...

Page 221: ...locking screw hole on the gearbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 1 xx1800003049 xx1800003050 Continues on next page Product manual IRB 1100 221 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 222: ...ng liquid after refitting Refitting the pulley cover Note Action Screw M3x8 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the puller cover 1 Tightening torque 1 2 Nm xx1800003043 Reconnecting the SMB cabling Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 1 Continues on next page ...

Page 223: ...h cable straps CAUTION Correct cable routing is highly important If the cables are routed and secured incorrectly the cables can be damaged 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 6 pcs Refit the SMB cover to the base 4 Tightening torque 1 2 Nm xx1800002467 Continues on next page Product manual IRB 1100 223 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replac...

Page 224: ...ing the brake release cabling and axis 1 motor connectors Note Action xx1800003054 Reconnect the connectors J1M BR MP1 FB1 Tip See the number markings on the connectors for help to find the corresponding connector 1 Continues on next page 224 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 225: ...om of the base Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 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 3 Continues on next page Product manual IRB 1100 2...

Page 226: ...ightening torque 1 2 Nm Refit the rear cover xx1800003057 Refitting the connector interface plate Note Action 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 1 Continues on next page 226 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reser...

Page 227: ...tmo 603 Geomet 500 6 pcs Refit the connector interface plate to the base 3 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page Product manual IRB 1100 227 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 228: ... CS cabling and Ethernet cabling if equipped Note Action xx1800002500 Reconnect the air hoses in a cross pattern to the Y shaped connectors Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y shaped connector 1 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connector...

Page 229: ... Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 2 Continues on next page Product manual IRB 1100 229 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continue...

Page 230: ... motor con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 Screw M4x16 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page 230 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 AB...

Page 231: ...re screw to the hole 7 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld tensiometer hooking to the screw and pull the tensiometer to reach the initial refer enced force 8 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page Product manual IRB 1100 231 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repai...

Page 232: ...nsion does not meet the require ment loosen the motor screws and readjust 11 xx1900000010 Remove the adjustment screw from the motor 12 xx1800002495 Reconnect the connector MP2 Tip See the number markings on the connectors for help to find the corresponding connector 13 Continues on next page 232 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair ...

Page 233: ...e corresponding connector 2 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 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Continues on next page Product manual IRB 1100 233 3HAC064992 001 Revision C Copyright ...

Page 234: ...Refit the covers Swing cover Swing support cover 3 Tightening torque 1 2 Nm xx1800003607 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 234 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4...

Page 235: ...B Business Portal www mypo rtal abb com Note Article number Spare part 3HAC075521 001 Lower cable harness basic 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet 3HAC069050 001 Swing 3HAC069039 001 Swing support Continues on next page Product manual IRB 1100 235 3HAC064992 001 Revision C Copyright 20192020 ABB...

Page 236: ...ed tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 607 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot i The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration t...

Page 237: ...ot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair pro...

Page 238: ... safeguarded space 3 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002488 Remove the swing support cover 2 Continues on next page 238 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 239: ...nnect the connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 5 xx1800002492 Remove the swing cover 6 Continues on next page Product manual IRB 1100 239 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved...

Page 240: ...refully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 10 Continues on next ...

Page 241: ... the cable package locking screw on the axis 1 gearbox from the swing and then loosen the locking screw 2 Remove the locking screw 3 Disconnecting the connectors at the division point Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 241 3HAC064992 001 Revision C Copyright 20192020...

Page 242: ...e the female head of the connectors from the connector plate 3 Separating the cable package from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002499 Remove the cable bracket 2 Continues on next page 242 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4...

Page 243: ...ors 2 xx1800002501 Disconnect the connectors J2 C1 J2 C2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting Tip The connector clip has to be pressed 1 and pushed forward 2 to separate the J2 C2 for Ethernet cabling xx1800002943 3 Continues on next page Product manual IRB 1100 243 3HAC064992 001 Revision C Copyright 20192020 ABB Al...

Page 244: ...dation by removing the foundation attachment screws and put the robot on its side 4 Disconnecting the SMB cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 2 Co...

Page 245: ... 3 xx1800002468 Disconnect the connectors SMB P7 SMB J1 SMB J2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Remove the SMB cover completely from the base 5 Opening the connector interface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues...

Page 246: ...ot be removed completely until the connectors are removed 2 xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 xx1800003056 Valid for cabling with bottom interface option 3309 1 Remove the base adapter 3 Continues on next page 246 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 247: ...hydraulic pressure and air pressure are turned off 1 xx1800003035 Valid for cabling with rear interface Remove the base bottom cover 2 xx1800003057 Valid for cabling with bottom interface option 3309 1 Remove the base rear cover 3 xx1800003036 Disconnect the earth cable 4 Continues on next page Product manual IRB 1100 247 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repai...

Page 248: ...cable position before disconnecting them to have as a reference when reconnecting 6 xx1800003039 Remove the female header of the J1M BR connect or from the connector plate 7 Continues on next page 248 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 249: ...are turned off 1 xx1800003041 Disconnect the connectors FB1 MP1 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 2 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 249 ...

Page 250: ...re and air pressure are turned off 1 xx1800003043 Remove the pulley cover 2 Pulling out the cable package Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 250 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 251: ...ove the pulley cover from the lower cable package 4 Removing the axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 251 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 252: ...t out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 4 Continues on next page 252 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 253: ...sure are turned off 1 xx1800003067 Remove the timing belt from its groove on the gearbox 2 Separating the base from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 253 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swin...

Page 254: ...em to have as a reference when refitting xx1800003068 2 xx1800003070 Separate the base from the swing CAUTION The axis 1 mechanical stop is accessible now Put it aside for later refitting xx1800003071 3 Continues on next page 254 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 255: ...e screws 2 xx1800003074 Pull out the gearbox 3 Separating the swing from the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 255 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 256: ...2192 Remove the screws Note Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 4 xx1800003078 Separate the swing from the lower arm 5 Continues on next page 256 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Rep...

Page 257: ...002192 Route the cable package through the swing sup port 2 xx2000000058 Apply grease Castrol Molub Alloy 777 1 NG to the inner surface of the lower arm where contacts the bearing on the swing support 3 Screw M5x16 12 9 Steel Black Oxide 6 pcs Refit the swing support Tip If the swing support is hard to closely fit to the lower arm use a plastic hammer to knock on the swing support lightly 4 Tighte...

Page 258: ... Gleitmo 603 Geomet 500 12 pcs Secure with screws 2 Tightening torque 1 6 Nm xx1800003073 Placing the axis 1 mechanical stop Note Action Mechanical stop axis 1 3HAC061947 001 Check the axis 1 mechanical stop Replace if damaged 1 Continues on next page 258 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 259: ...ng the swing when putting xx1800003619 2 Refitting the base to the swing Note Action Screw M4x16 12 9 Gleitmo 603 Geomet 500 13 pcs Refit the base to the swing Note Pay attention to the screw and washer location xx1800003068 1 Tightening torque 4 4 Nm xx1800003069 Continues on next page Product manual IRB 1100 259 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 ...

Page 260: ...that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003602 Check the cooling pad Replace if damaged 2 xx1800003085 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley 3 Continues on next page 260 Product manual IRB 1100 3HAC064992 001 Revisio...

Page 261: ...ns cor rectly in the groove of the pulley 4 Screw M4x16 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800003065 Adjusting the axis 1 timing belt tension Note Action xx1900000040 Use a handheld tensiometer hooking to the motor 1 Continues on next page Product manual IRB 1100 261 3HAC064992 001 Revision C Copyright ...

Page 262: ...e button Note Action brake release button assembly tool included in the special toolkit 3HAC071022 001 Tighten the brake release button using the tool 1 xx1800003040 Refitting the lower cable package through the axis 1 gearbox Notice that the procedure differs depending on if the connector interface is located either at the rear or at the bottom of the base Note Action xx1800003046 Refit the pulle...

Page 263: ...re twisted or strained Reroute if necessary 2 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page Product manual IRB 1100 263 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 ...

Page 264: ...r hoses are twisted or strained Reroute if necessary 3 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page 264 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights re...

Page 265: ...ocking screw hole on the gearbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 1 xx1800003049 xx1800003050 Continues on next page Product manual IRB 1100 265 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 266: ...ng liquid after refitting Refitting the pulley cover Note Action Screw M3x8 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the puller cover 1 Tightening torque 1 2 Nm xx1800003043 Reconnecting the SMB cabling Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 1 Continues on next page ...

Page 267: ... the cables can be damaged 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 6 pcs Refit the SMB cover to the base 4 Tightening torque 1 2 Nm xx1800002467 Refitting the connector interface plate Note Action 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 1 Continues on next page Produ...

Page 268: ...mo 603 Geomet 500 6 pcs Refit the connector interface plate to the base 3 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page 268 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 269: ...ng the brake release cabling and axis 1 motor connectors Note Action xx1800003054 Reconnect the connectors J1M BR MP1 FB1 Tip See the number markings on the connectors for help to find the corresponding connector 1 Continues on next page Product manual IRB 1100 269 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 270: ...om of the base Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 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 3 Continues on next page 270 Product manual IRB 11...

Page 271: ...o the foundation Note Action CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 1 Attachment screws M12x25 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 2 Washers 24 x 13 x 2 5 steel hard ness class 300HV Tightening Torque 50 Nm 5 Nm Continues on next page Product manual I...

Page 272: ... to the same Y shaped connector 1 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for help to find the corresponding connector 2 Securing the cable package to the swing Note Action Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 1 Tightening torque 0 8 Nm xx1800002499 Continues on next page 272 Product manual IRB 1100 3HAC064992 ...

Page 273: ...s Remove the screws Replace with a new cooling pad and then refit the screws 3 Tightening torque 1 2 Nm xx1800003026 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 Continues on next page Product manual IRB 1...

Page 274: ...the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 6 xx1900000010 Install an M6x25 or longer adjustment screw to the motor Note Do not insert the entire screw to the hole 7 Continues on next page 274 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 275: ... Tightening torque 3 5 Nm xx1800002493 Secure the motor with the screws 9 Used belt 163 174 Hz Use an acoustic tensiometer to measure the tim ing belt tension 10 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 11 Continues on next page Product manual IRB 1100 275 3HAC064992 001 Revision C Copyright 20192020 ABB A...

Page 276: ...s for help to find the corresponding connector 13 Reconnecting the connectors at the division point Note Action xx1800003029 Insert the female header of the connectors to the connector plate 1 Continues on next page 276 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 277: ... incorrectly the cables can be damaged 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 Continues on next page Product manual IRB 1100 277 3HAC064...

Page 278: ...oncluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 278 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 279: ... the latest spare parts of the IRB 1100 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC069056 001 Lower arm IRB 1100 4 0 58 3HAC069055 001 Lower arm IRB 1100 4 0 475 3HAC069058 001 Lower arm support 3HAC066144 001 Motor with flange axis 2 Continues on next page Product manual IRB 1100 279 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Rep...

Page 280: ...as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot i The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for measuring the timing belt tension Acoustic tensiome...

Page 281: ...alibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration fo...

Page 282: ...aulic pressure supply air pressure supply to the robot before entering the safeguarded space 3 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002488 Remove the swing support cover 2 Continues on next page 282 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights r...

Page 283: ...ect the connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 5 xx1800002492 Remove the swing cover 6 Continues on next page Product manual IRB 1100 283 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5...

Page 284: ...fully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 10 Continues on next pa...

Page 285: ...1 xx1800002497 Disconnect the connectors J2 FB3 4 5 6 J2 MP3 4 5 6 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 2 xx1800002498 Snap loose and remove the female head of the connectors from the connector plate 3 Continues on next page Product manual IRB 1100 285 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reser...

Page 286: ...the air hoses CP CS cabling and Ethernet cabling if equipped Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002500 Disconnect the air hoses from the Y shaped con nectors 2 Continues on next page 286 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the...

Page 287: ... to separate the J2 C2 for Ethernet cabling xx1800002943 3 Separating the upper cable harness from the axis 2 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003002 Remove the cable bracket 2 Continues on next page Product manual IRB 1100 287 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5...

Page 288: ... plate The connector plate cannot be removed completely until the connectors are re move from the plate as shown in following step 3 xx1800003005 Slide the connectors out of the connector plate and disconnect the connectors FB3 MP3 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Continues on next page 288 Product manual IRB 1...

Page 289: ...draulic pressure and air pressure are turned off 1 xx1800003007 Remove the lower arm cover 2 xx1800003008 Loosen the screws and move the motor slightly to slacken the timing belt 3 Continues on next page Product manual IRB 1100 289 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 290: ...om the casting Pay attention not to scratch the casting or damage the pad 5 xx1800003010 Remove the timing belt from its groove on the motor 6 Removing the swing support Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 290 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All right...

Page 291: ...e are turned off 1 xx1900002203 Remove the screws Note Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 2 xx1800003081 Separate the swing from the lower arm Tip If the swing is hard to loosen from the housing use a plastic hammer to knock on the swing light...

Page 292: ...e screws 2 xx1800003083 Pull out the gearbox 3 Pulling out the upper cable package Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 292 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 293: ...er arm support Tip If the lower arm support is hard to loosen from the housing use a plastic hammer to knock on the lower arm support lightly 2 Separating the lower arm from the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 293 3HAC064992 001 Revision C Copyright 201920...

Page 294: ...r arm lightly 3 Refitting the lower arm Use these procedures to refit the lower arm Refitting the lower arm to the housing Note Action Flange screws 16 pcs Refit the lower arm to the housing Note Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 1 Tightening...

Page 295: ... 12 9 Steel Black Oxide 5 pcs Refit the lower arm support 2 Tightening torque 8 Nm xx1800003088 Route the cable package through the lower arm support 3 Refitting the axis 2 gearbox Note Action xx1800003083 Refit the axis 2 gearbox 1 Continues on next page Product manual IRB 1100 295 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continue...

Page 296: ... always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 1 Tightening torque 4 4 Nm xx1900002203 Securing the swing support Note Action xx2000000058 Apply grease Castrol Molub Alloy 777 1 NG to the inner surface of the lower arm where contacts the bearing on the swing support 1 Continues on next page 296 Product manual IRB 1100 3HAC064992 0...

Page 297: ...uide the upper cable package to go through the lower arm and down to the swing When inserting the cable package leave the axis 3 motor connectors in the lower arm Tip Wrap the connectors with the masking tape 1 Refitting the axis 3 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Continues on next page Product manual IRB 1100 297 3...

Page 298: ...d motor con nector xx1800003021 Orient the motor correctly and fit it into the lower arm 3 Screw M4x12 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 4 Washer 3HAC063985 001 3 pcs xx1800003009 Continues on next page 298 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower a...

Page 299: ...rooves of the pul leys 5 xx1900000009 Install an M4x25 or longer adjustment screw to the motor Note Do not insert the entire screw to the hole 6 Continues on next page Product manual IRB 1100 299 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 300: ...ghtening torque 3 Nm Secure the motor with the screws 8 xx1800003008 Used belt 102 109 Hz Use an acoustic tensiometer to measure the tim ing belt tension 9 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 10 Continues on next page 300 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rig...

Page 301: ... the corresponding connector 1 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 2 Screw M2 5x6 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Continues on next page Product manual IRB 1100 301 3HAC064992 001 Revision C Copyrig...

Page 302: ...Reconnecting the air hoses CP CS cabling and Ethernet cabling if equipped Note Action xx1800002500 Reconnect the air hoses in a cross pattern to the Y shaped connectors Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y shaped connector 1 Continues on next page 302 Product manual IRB 1100 3HAC064992 001...

Page 303: ...ew M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 1 Tightening torque 0 8 Nm xx1800002499 Refitting the axis 2 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Continues on next page Product manual IRB 1100 303 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower ar...

Page 304: ... the screws 3 Tightening torque 1 2 Nm xx1800003026 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 Continues on next page 304 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All righ...

Page 305: ...e timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 6 xx1900000010 Install an M6x25 or longer adjustment screw to the motor Note Do not insert the entire screw to the hole 7 Continues on next page Product manual IRB 1100 305 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 306: ...ightening torque 3 5 Nm xx1800002493 Secure the motor with the screws 9 Used belt 163 174 Hz Use an acoustic tensiometer to measure the tim ing belt tension 10 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 11 Continues on next page 306 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All...

Page 307: ...for help to find the corresponding connector 13 Reconnecting the connectors at the division point Note Action xx1800003029 Insert the female header of the connectors to the connector plate 1 Continues on next page Product manual IRB 1100 307 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 308: ...d incorrectly the cables can be damaged 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Refitting the covers Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 Continues on next page 308 Product manual IRB 1100 3HAC064992 0...

Page 309: ... Nm xx1800003610 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 1100 309 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 310: ...myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC069094 001 Process hub basic 3HAC069095 001 Process hub CP CS and air hose without Ethernet 3HAC069096 001 Process hub CP CS and air hose with Ethernet 3HAC069053 001 Housing 3HAC073518 001 Gear unit with pulley axis 3 3HAC073218 001 Labyrinth sealing ring Continues on next page 310 Product manual IRB 1100 3HAC064992 00...

Page 311: ...be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for measuring the timing belt tension Acoustic tensiometer Used for measuring the timing belt tension Tensiometer Included in the special toolkit 3HAC071022 001 M3x25 eye bolt Included in the special toolkit 3HAC071022 001 Used to...

Page 312: ...ven in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about r...

Page 313: ...ce 3 Removing the process hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002944 Remove the screws and carefully open the cover CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors are disconnected as shown in following steps 2 Continues on next p...

Page 314: ...ct the con nector J5 UL 4 xx1800002947 For robots with CP CS cabling Disconnect the connector J5 C1 5 J5 C2 connector assembly tool xx1800002948 For robots with Ethernet cabling Disconnect the connector J5 C2 using the tool 6 Continues on next page 314 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 315: ...cting the axis 5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002950 Access the connector FB5 from the process hub and disconnect the connector 2 Continues on next page Product manual IRB 1100 315 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housin...

Page 316: ...ir pressure are turned off 1 xx1800002994 Disconnect the connectors MP6 FB6 2 Removing the axis 6 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 316 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 317: ... Remove the timing belt from its groove on the motor 5 Loosening the cable package from axis 4 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 317 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 318: ...der unit to access the cable package locking screw on the axis 4 gearbox and then loosen the locking screw 3 xx1800003001 Disconnecting the axis 4 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 318 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights rese...

Page 319: ...upper cable package from the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 319 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 320: ...R Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003092 Remove the lower arm support cover 2 Continues on next page 320 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 321: ...lies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003094 Loosen the screws and move the motor slightly to slacken the timing belt 2 xx1800003095 Remove the screws and washers 3 Continues on next page Product manual IRB 1100 321 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 322: ...ing or damage the pad 4 xx1800003096 Remove the timing belt from its groove on the motor 5 Removing the pulley cover and axis 4 timing belt Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003097 Remove the pulley cover 2 Continues on next page 322 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB ...

Page 323: ...screws Note Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 2 xx1800003075 Valid for IRB 1100 4 0 475 Separate the wrist from the housing 3 Continues on next page Product manual IRB 1100 323 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reser...

Page 324: ...d off 1 xx1800003003 Remove the lower arm support cover 2 xx1800003004 Remove the connector plate CAUTION Be aware of the cablings that are attached to the connector plate The connector plate cannot be removed completely until the connectors are re move from the plate as shown in following step 3 Continues on next page 324 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB Al...

Page 325: ... the lower arm support Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003088 Remove the lower arm support Tip If the lower arm support is hard to loosen from the housing use a plastic hammer to knock on the lower arm support lightly 2 Continues on next page Product manual IRB 1100 325 3HAC064992 001 Revision C Copyrigh...

Page 326: ...Remove the lower arm cover 2 xx1800003008 Loosen the screws and move the motor slightly to slacken the timing belt 3 xx1800003022 Remove the timing belt from its grooves on the motor and gearbox 4 Continues on next page 326 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 327: ...e robot at delivery Contact ABB for more informa tion 2 xx1800003090 Separate the lower arm from the housing Tip If the lower arm is hard to loosen from the hous ing use a plastic hammer to knock on the lower arm lightly 3 Removing the axis 3 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Produ...

Page 328: ...ng 2 xx1900001417 Remove the labyrinth sealing ring lightly and evenly 3 xx1800003284 Remove the screws 4 Continues on next page 328 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 329: ... gearbox Note Action xx1800003285 Refit the axis 3 gearbox 1 Screw M3x30 12 9 Gleitmo 603 Geomet 500 12 pcs Secure with screws 2 Tightening torque 1 8 Nm xx1800003284 Continues on next page Product manual IRB 1100 329 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 330: ...ell fitted to the axis 3 gearbox without any deflection 4 Screw M3x4 2 pcs Apply a little Loctite 243 to the screws and secure the labyrinth sealing ring with the screws 5 Tightening torque 0 8 Nm xx1900001425 Continues on next page 330 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 331: ...xx1900002190 Securing the lower arm support Note Action xx2000000059 Apply grease Castrol Molub Alloy 777 1 NG to the inner surface of the housing where contacts the bearing on the lower arm support 1 Screw M5x16 12 9 Steel Black Oxide 5 pcs Refit the lower arm support 2 Tightening torque 8 Nm xx1800003088 Route the cable package through the lower arm support 3 Continues on next page Product manua...

Page 332: ...ectly in the grooves of the pul leys 1 xx1900000009 Install an M4x25 or longer adjustment screw to the motor Note Do not insert the entire screw to the hole 2 Continues on next page 332 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 333: ...00 3 pcs Secure the motor with the screws 4 Washer 3HAC063985 001 3 pcs Tightening torque 3 Nm xx1800003008 Used belt 102 109 Hz Use an acoustic tensiometer to measure the tim ing belt tension 5 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 6 Continues on next page Product manual IRB 1100 333 3HAC064992 001 Rev...

Page 334: ... the corresponding connector 1 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 2 Screw M2 5x6 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Continues on next page 334 Product manual IRB 1100 3HAC064992 001 Revision C Copyrig...

Page 335: ... Note Action xx1800003075 Valid for IRB 1100 4 0 475 Refit the the wrist to the housing 1 xx1800003100 Valid for IRB 1100 4 0 58 Refit the extender unit and wrist to the housing 2 Continues on next page Product manual IRB 1100 335 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 336: ... Nm xx1900002191 Refitting the axis 4 timing belt and pulley cover Note Action xx1800003098 Install the timing belt to the gearbox pulley and verify that the belt runs correctly in the groove of the pulley 1 Screw M3x8 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the pulley cover 2 Tightening torque 1 2 Nm xx1800003097 Continues on next page 336 Product manual IRB 1100 3HAC064992 001 Revision C Copyrig...

Page 337: ...3HAC071021 001 xx1800003605 Check the cooling pad Replace if damaged 2 axis 4 motor fitting tool included in the special toolkit 3HAC071022 001 Use the motor fitting tool to fix the timing belt 3 xx1900000044 Continues on next page Product manual IRB 1100 337 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 338: ...ess on the timing belt 4 xx1800003617 Install the timing belt to the motor pulley 5 Screw M3x12 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC064765 001 3 pcs xx1800003095 Remove the motor fitting tool 7 Continues on next page 338 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 ...

Page 339: ... the housing 1 xx1900000037 Fit an M3x25 eye bolt o the screw hole 2 xx1900000038 Use a handheld tensiometer hooking to the eye bolt 3 Continues on next page Product manual IRB 1100 339 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 340: ...8 7 31 5 N xx1900000039 Tightening torque 1 4 Nm xx1800003094 Secure the motor with the screws 5 Plug screw 3HAC064146 001 Remove eye bolt and refit the screw and washer below the housing 6 Tightening torque 2 Nm Continues on next page 340 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 341: ... locking screw hole on the gearbox xx1800003017 Insert the cable package from the lower arm sup port into the housing and through the axis 4 gearbox Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 1 Continues on next page Product manual IRB 1100 341 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reser...

Page 342: ...ng screw hole on the gearbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 1 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page 342 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the hou...

Page 343: ...liquid residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for IRB 1100 4 0 58 xx1800003001 Plug screw 3HAC064146 001 Valid for IRB 1100 4 0 58 3 Tightening torque 2 Nm xx1800003000 Refit the plug screw and washer on the extender unit Continues on next page Product manual IRB 1100 343 3HAC064992 001 Revision C Copyright 20192020...

Page 344: ...03 Geomet 500 2 pcs Tightening torque 0 6 Nm xx1800003014 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 2 Continues on next page 344 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 345: ...P4 Tip See the number markings on the connectors for help to find the corresponding connector 2 Refitting the axis 6 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Continues on next page Product manual IRB 1100 345 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 346: ... connectors MP5 and MP6 accessible from wrist side 2 Screw M3x12 12 9 Gleitmo 603 Geomet 500 3 pcs xx1800002996 Refit the screws and washers Note Do not tighten the screws yet 3 xx1800003024 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 4 Continues on next page 346 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 A...

Page 347: ...tial referenced force for new belt 12 8 14 xx1900000026 Tightening torque 1 4 Nm xx1800002995 Secure the motor with the screws 7 Used belt 81 3 86 9 Hz Use an acoustic tensiometer to measure the tim ing belt tension 8 New belt 90 114 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 9 Continues on next page Product manual IRB 1100 ...

Page 348: ...o find the corresponding connector 1 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 2 Insert the cabling and connectors into the wrist 3 Continues on next page 348 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 1 Rep...

Page 349: ...nectors into the wrist 3 Refitting the process hub Note Action xx1800002946 For robots with safety lamp option 3308 1 Reconnect the connector J5 UL and place the connector behind the air hose connectors 1 xx1800002945 Reconnect the air hoses in a cross pattern Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the...

Page 350: ...e tool 4 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 5 Screw M3x8 12 9 Gleitmo 603 Geomet 500 4 pcs Refit the cover 6 Tightening torque 1 2 Nm xx1800002944 Continues on next page 350 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reser...

Page 351: ... covers Lower arm cover Lower arm support cover Housing cover 3 Tightening torque 1 2 Nm xx1800003611 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 1100 351 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved...

Page 352: ...tender unit connecting the housing and wrist which is located as shown in the figure xx1800002476 The wrist is located as shown in the figure Continues on next page 352 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist ...

Page 353: ...CP CS and air hose with Ethernet Used for IRB 1100 4 0 58 3HAC069037 001 Extender unit 3HAC075794 001 Wrist 3HAC073519 001 Gear unit with pulley axis 4 3HAC066184 001 Motor with flange axis 4 3HAC061937 001 Timing belt axis 4 3HAC066200 001 Motor with flange axis 5 3HAC061938 001 Timing belt axis 5 3HAC066201 001 Motor with flange axis 6 3HAC061939 001 Timing belt axis 6 Continues on next page Pro...

Page 354: ...n Used to release the motor brakes 24 VDC power supply Used for measuring the timing belt tension Acoustic tensiometer Used for measuring the timing belt tension Tensiometer Included in the special toolkit 3HAC071022 001 Used to refit the axis 4 motor axis 4 motor fitting tool Included in the special toolkit 3HAC071022 001 M3x25 eye bolt Included in the special toolkit 3HAC071022 001 Used to remov...

Page 355: ...te reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration r...

Page 356: ...oving the process hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002944 Remove the screws and carefully open the cover CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors are disconnected as shown in following steps 2 Continues on next page 356 ...

Page 357: ...on nector J5 UL 4 xx1800002947 For robots with CP CS cabling Disconnect the connector J5 C1 5 J5 C2 connector assembly tool xx1800002948 For robots with Ethernet cabling Disconnect the connector J5 C2 using the tool 6 Continues on next page Product manual IRB 1100 357 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued...

Page 358: ...e axis 5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002950 Access the connector FB5 from the process hub and disconnect the connector 2 Continues on next page 358 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit ...

Page 359: ...ure are turned off 1 xx1800002994 Disconnect the connectors MP6 FB6 2 Removing the axis 6 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 359 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 360: ...997 Remove the timing belt from its groove on the motor 5 Removing the axis 5 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 360 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 361: ... Remove the screws and washers 3 Carefully lift out the motor 4 xx1800003295 Remove the timing belt from its groove on the motor 5 Continues on next page Product manual IRB 1100 361 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 362: ... axis 4 gearbox from the wrist and then loosen the locking screw 2 xx1800003000 Valid for IRB 1100 4 0 58 Remove the plug screw and washer on the ex tender unit to access the cable package locking screw on the axis 4 gearbox and then loosen the locking screw 3 xx1800003001 Continues on next page 362 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repa...

Page 363: ...800003012 Disconnect the motor connectors FB4 MP4 3 Separating the upper cable package from the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 363 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Co...

Page 364: ...ure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003092 Remove the lower arm support cover 2 Continues on next page 364 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 365: ... electrical power hydraulic pressure and air pressure are turned off 1 xx1800003094 Loosen the screws and move the motor slightly to slacken the timing belt 2 xx1800003095 Remove the screws and washers 3 Continues on next page Product manual IRB 1100 365 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 366: ...amage the pad 4 xx1800003096 Remove the timing belt from its groove on the motor 5 Removing the pulley cover and axis 4 timing belt Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003097 Remove the pulley cover 2 Continues on next page 366 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All righ...

Page 367: ...ote Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 2 xx1800003299 Valid for IRB 1100 4 0 475 Separate the wrist from the housing 3 Continues on next page Product manual IRB 1100 367 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Re...

Page 368: ... Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003300 Remove the screws 2 xx1800003310 Pull out the gearbox 3 Continues on next page 368 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 369: ...the extender unit and wrist Use these procedures to refit the extender unit and wrist Refitting the extender unit to the wrist Notice that this procedure is valid for IRB 1100 4 0 58 Note Action Screw M3x16 12 9 Gleitmo 603 Geomet 500 Black Oxide 16 pcs Refit the extender unit to the wrist 1 Tightening torque 2 Nm xx1800003311 Continues on next page Product manual IRB 1100 369 3HAC064992 001 Revis...

Page 370: ...arbox and extender unit or wrist are aligned with each other 1 Valid for IRB 1100 4 0 475 xx1800003313 Valid for IRB 1100 4 0 58 xx1800003312 Continues on next page 370 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 371: ...n xx1800003075 Valid for IRB 1100 4 0 475 Refit the the wrist to the housing 1 xx1800003100 Valid for IRB 1100 4 0 58 Refit the extender unit and wrist to the housing 2 Continues on next page Product manual IRB 1100 371 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 372: ...00002191 Refitting the axis 4 timing belt and pulley cover Note Action xx1800003098 Install the timing belt to the gearbox pulley and verify that the belt runs correctly in the groove of the pulley 1 Screw M3x8 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the pulley cover 2 Tightening torque 1 2 Nm xx1800003097 Continues on next page 372 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192...

Page 373: ...21 001 xx1800003605 Check the cooling pad Replace if damaged 2 axis 4 motor fitting tool included in the special toolkit 3HAC071022 001 Use the motor fitting tool to fix the timing belt 3 xx1900000044 Continues on next page Product manual IRB 1100 373 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 374: ...he timing belt 4 xx1800003617 Install the timing belt to the motor pulley 5 Screw M3x12 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC064765 001 3 pcs xx1800003095 Remove the motor fitting tool 7 Continues on next page 374 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Repl...

Page 375: ...sing 1 xx1900000037 Fit an M3x25 eye bolt o the screw hole 2 xx1900000038 Use a handheld tensiometer hooking to the eye bolt 3 Continues on next page Product manual IRB 1100 375 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 376: ... N xx1900000039 Tightening torque 1 4 Nm xx1800003094 Secure the motor with the screws 5 Plug screw 3HAC064146 001 Remove eye bolt and refit the screw and washer below the housing 6 Tightening torque 2 Nm Continues on next page 376 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 377: ... screw hole on the gearbox xx1800003017 Insert the cable package from the lower arm sup port into the housing and through the axis 4 gearbox Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 1 Continues on next page Product manual IRB 1100 377 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Re...

Page 378: ... hole on the gearbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 1 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page 378 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender un...

Page 379: ...esidues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for IRB 1100 4 0 58 xx1800003001 Plug screw 3HAC064146 001 Valid for IRB 1100 4 0 58 3 Tightening torque 2 Nm xx1800003000 Refit the plug screw and washer on the extender unit Continues on next page Product manual IRB 1100 379 3HAC064992 001 Revision C Copyright 20192020 ABB All...

Page 380: ...t 500 2 pcs Tightening torque 0 6 Nm xx1800003014 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 2 Continues on next page 380 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Con...

Page 381: ...ee the number markings on the connectors for help to find the corresponding connector 2 Refitting the axis 5 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Continues on next page Product manual IRB 1100 381 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Co...

Page 382: ...s MP5 and MP6 accessible from wrist side 2 Screw M3x12 12 9 Gleitmo 603 Geomet 500 3 pcs xx1800003291 Refit the screws and washers Note Do not tighten the screws yet 3 xx1800003292 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 4 Continues on next page 382 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rig...

Page 383: ...erenced force for new belt 19 4 21 2 N xx1900000027 Tightening torque 1 4 Nm xx1800003290 Secure the motor with the screws 7 Used belt 151 162 Hz Use an acoustic tensiometer to measure the tim ing belt tension 8 New belt 167 213 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 9 Continues on next page Product manual IRB 1100 383 3...

Page 384: ...ector xx1800003023 Orient the motor correctly and fit it into the lower arm Tip Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side 2 Screw M3x12 12 9 Gleitmo 603 Geomet 500 3 pcs xx1800002996 Refit the screws and washers Note Do not tighten the screws yet 3 Continues on next page 384 Product manual IRB 1100 3HAC064992 001 Revi...

Page 385: ...force for used belt 8 96 9 8 N for reference only Use a handheld tensiometer hooking to the screw and pull the tensiometer to reach the initial refer enced force 6 Initial referenced force for new belt 12 8 14 xx1900000026 Tightening torque 1 4 Nm xx1800002995 Secure the motor with the screws 7 Continues on next page Product manual IRB 1100 385 3HAC064992 001 Revision C Copyright 20192020 ABB All ...

Page 386: ...n xx1800002994 Reconnect the connectors FB6 MP6 Tip See the number markings on the connectors for help to find the corresponding connector 1 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 2 Insert the cabling and connectors into the wrist 3 Continues on next page 386 Product...

Page 387: ...into the wrist 3 Refitting the process hub Note Action xx1800002946 For robots with safety lamp option 3308 1 Reconnect the connector J5 UL and place the connector behind the air hose connectors 1 xx1800002945 Reconnect the air hoses in a cross pattern Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y ...

Page 388: ... 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 5 Screw M3x8 12 9 Gleitmo 603 Geomet 500 4 pcs Refit the cover 6 Tightening torque 1 2 Nm xx1800002944 Continues on next page 388 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Re...

Page 389: ... covers Lower arm support cover Housing cover 3 Tightening torque 1 2 Nm xx1800003612 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 1100 389 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 6 2 ...

Page 390: ... Business Portal www mypo rtal abb com Note Article number Spare part 3HAC066143 001 Motor with flange axis 1 3HAC061935 001 Timing belt axis 2 Standard configuration used for robots with rear connector inter face 3HAC060463 001 Base bottom cover Used for robots with bottom con nector interface 3HAC070312 001 Base rear cover Continues on next page 390 Product manual IRB 1100 3HAC064992 001 Revisio...

Page 391: ...d at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Deciding calibration routine Decide which calibration routine to be used bas...

Page 392: ... values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor Use these procedures to remove the axis 1 motor Preparations before removing the axis 1 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginn...

Page 393: ...ot secured to the foundation 3 xx1800003033 Loosen the robot from the foundation by removing the foundation attachment screws and put the robot on its side 4 Opening the connector interface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 393 3HAC064992 001 Revision C Copyri...

Page 394: ...be removed completely until the connectors are removed 2 xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 xx1800003056 Valid for cabling with bottom interface option 3309 1 Remove the base adapter 3 Continues on next page 394 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continu...

Page 395: ...id for cabling with rear interface Remove the base bottom cover 2 xx1800003057 Valid for cabling with bottom interface option 3309 1 Remove the base rear cover 3 Disconnecting axis 1 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 395 3HAC064992 001 Revision C Co...

Page 396: ... head of the connectors from the connector plate 3 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003042 Remove the cable bracket 2 Continues on next page 396 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 1 Replacing ...

Page 397: ...sure are turned off 1 xx1800003064 Loosen the screws and move the motor slightly to slacken the timing belt 2 xx1800003065 Remove the screws and washers 3 Continues on next page Product manual IRB 1100 397 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 398: ... belt from its groove on the motor 5 Refitting the motor Use these procedures to refit the axis 1 motor Refitting the axis 1 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003602 Check the cooling pad Replace if damaged 2 Continues on next page 398 Product manual IRB 1100 ...

Page 399: ... 3 xx1800003615 Install the timing belt to the motor pulley 4 Screw M4x16 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800003065 Continues on next page Product manual IRB 1100 399 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 400: ...removed Pay attention to the force application direction 2 New belt 83 2 90 8 N for reference only xx1900000041 Tightening torque 3 Nm Secure the motor with the screws 3 Securing the lower cable package to the base Note Action Screw M2 5x6 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 1 Tightening torque 0 6 Nm xx1800003042 Continues on next page 400 Product manual IRB 1100 3HAC064992 ...

Page 401: ...d and secured incorrectly the cables can be damaged 1 Screw M3x8 Steel 8 8 A2F 7 pcs Valid for cabling with bottom interface option 3309 1 2 Tightening torque 1 2 Nm Refit the base adapter xx1800003056 Continues on next page Product manual IRB 1100 401 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 402: ...ted either at the rear or at the bottom of the base Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 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 3 Continues o...

Page 403: ...he foundation Note Action CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 1 Attachment screws M12x25 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 2 Washers 24 x 13 x 2 5 steel hard ness class 300HV Tightening Torque 50 Nm 5 Nm Continues on next page Product manual IRB ...

Page 404: ...ation on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 404 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 405: ...number Spare part 3HAC066144 001 Motor with flange axis 2 3HAC061935 001 Timing belt axis 2 3HAC069051 001 Swing cover 3HAC069052 001 Swing support cover Cooling pads are wear parts One cooling pad sheet contains 6 pieces of small pad Replace if damaged with one piece each time 3HAC071020 001 Cooling pad for axis 1 and 2 mo tors 9x4 3x1 Steel 3HAC063985 001 Washer Continues on next page Product ma...

Page 406: ...FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair w...

Page 407: ... values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor Use these procedures to remove the axis 2 motor Preparations before removing the axis 2 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginn...

Page 408: ...are attached to the connector plate The connector plate cannot be removed completely until the connectors are re move from the plate 3 xx1800002490 Disconnect the connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Continues on next page 408 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB...

Page 409: ...MP2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 7 xx1800002493 Loosen the screws and move the motor slightly to slacken the timing belt 8 Continues on next page Product manual IRB 1100 409 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 motor Continued ...

Page 410: ...ad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 10 xx1800002496 Remove the timing belt from its groove on the motor 11 Removing the cooling pad Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 410 Product manua...

Page 411: ...HAC071020 001 Attach the cooling pad together with the bracket to the motor 1 Make sure the bracket does not exceed the motor flange and the screw holes are aligned Screw M3x5 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cooling pad bracket 2 Tightening torque 1 2 Nm xx1800003026 Refitting the axis 2 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean...

Page 412: ...2 Screw M4x16 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 3 Washer 3HAC063985 001 3 pcs xx1800002494 xx1800003028 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 4 Continues on next page 412 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved ...

Page 413: ...ndheld tensiometer hooking to the screw and pull the tensiometer to reach the initial refer enced force 6 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Tightening torque 3 5 Nm xx1800002493 Secure the motor with the screws 7 Continues on next page Product manual IRB 1100 413 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 m...

Page 414: ...ent screw from the motor 10 xx1800002495 Reconnect the connector MP2 Tip See the number markings on the connectors for help to find the corresponding connector 11 Reconnecting the connector J2 FB2 Note Action xx1800002491 Insert the female header of the J2 FB2 connector to the connector plate 1 Continues on next page 414 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All ...

Page 415: ...are routed and secured incorrectly the cables can be damaged 4 Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the connector plate 5 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 Continues on next page Product manua...

Page 416: ...luding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 416 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 motor Continued ...

Page 417: ...er Spare part 3HAC066183 001 Motor with flange axis 3 3HAC061936 001 Timing belt axis 3 3HAC069057 001 Lower arm cover 3HAC069059 001 Lower arm support cover Cooling pads are wear parts One cooling pad sheet includes 10 pieces of small pad Replace if damaged with one piece each time 3HAC071021 001 Cooling pad for axis 3 and 4 mo tors 9x4 3x1 Steel 3HAC063985 001 Washer Continues on next page Produ...

Page 418: ...FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair w...

Page 419: ... values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor Use these procedures to remove the axis 3 motor Preparations before removing the axis 3 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginn...

Page 420: ...plate The connector plate cannot be removed completely until the connectors are re move from the plate as shown in following step 3 xx1800003005 Slide the connectors out of the connector plate and disconnect the connectors FB3 MP3 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Continues on next page 420 Product manual IRB 11...

Page 421: ...raulic pressure and air pressure are turned off 1 xx1800003007 Remove the lower arm cover 2 xx1800003008 Loosen the screws and move the motor slightly to slacken the timing belt 3 Continues on next page Product manual IRB 1100 421 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 motor Continued ...

Page 422: ... the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 5 xx1800003010 Remove the timing belt from its groove on the motor 6 Continues on next page 422 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 motor Continued ...

Page 423: ...4 mo tors 3HAC071021 001 xx1800003604 Check the cooling pad Replace if damaged 2 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003021 Orient the motor correctly and fit it into the lower arm 3 Continues on next page Product manual IRB 1100 423 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 3 Rep...

Page 424: ...timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 5 xx1900000009 Install an M4x25 or longer adjustment screw to the motor Note Do not insert the entire screw to the hole 6 Continues on next page 424 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 motor Continued ...

Page 425: ...htening torque 3 Nm Secure the motor with the screws 8 xx1800003008 Used belt 102 109 Hz Use an acoustic tensiometer to measure the tim ing belt tension 9 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 10 Continues on next page Product manual IRB 1100 425 3HAC064992 001 Revision C Copyright 20192020 ABB All righ...

Page 426: ...he corresponding connector 1 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 2 Screw M2 5x6 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Continues on next page 426 Product manual IRB 1100 3HAC064992 001 Revision C Copyright...

Page 427: ... cable package 2 Screw M3x8 12 9 Gleitmo 603 Geomet 500 Refit the covers Lower arm cover Lower arm support cover 3 Tightening torque 1 2 Nm xx1800003608 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 1100 427 3HAC064992 001 Re...

Page 428: ...e Article number Spare part 3HAC066184 001 Motor with flange axis 4 3HAC061937 001 Timing belt axis 4 3HAC069054 001 Housing cover Cooling pads are wear parts One cooling pad sheet includes 10 pieces of small pad Replace if damaged with one piece each time 3HAC071021 001 Cooling pad for axis 3 and 4 mo tors 7x3 2x1 5 Steel 3HAC064765 001 Washer Continues on next page 428 Product manual IRB 1100 3H...

Page 429: ...alibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen actio...

Page 430: ... values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor Use these procedures to remove the axis 4 motor Preparations before removing the axis 4 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginn...

Page 431: ...housing cover 2 xx1800003012 Disconnect the motor connectors FB4 MP4 3 Removing the axis 4 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 431 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 432: ...t the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 4 Continues on next page 432 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 433: ...tion Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Cooling pad for axis 3 and 4 mo tors 3HAC071021 001 xx1800003605 Check the cooling pad Replace if damaged 2 Continues on next page Product manual IRB 1100 433 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 434: ...ow in regard to the encircled motor con nector xx1800003287 Orient the motor correctly and fit it into the hous ing Note Make sure the motor flange does not press on the timing belt 4 xx1800003617 Install the timing belt to the motor pulley 5 Continues on next page 434 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 m...

Page 435: ...move the motor fitting tool 7 Adjusting the axis 4 timing belt tension Note Action xx1900000036 Remove the screw and washer below the housing 1 xx1900000037 Fit an M3x25 eye bolt o the screw hole 2 Continues on next page Product manual IRB 1100 435 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 436: ...lication direction 4 New belt 28 7 31 5 N xx1900000039 Tightening torque 1 4 Nm xx1800003094 Secure the motor with the screws 5 Plug screw 3HAC064146 001 Remove eye bolt and refit the screw and washer below the housing 6 Tightening torque 2 Nm Continues on next page 436 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 ...

Page 437: ...s on the connectors for help to find the corresponding connector 2 Refitting the housing cover Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 Continues on next page Product manual IRB 1100 437 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 4 Replaci...

Page 438: ...cedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 438 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 439: ...myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC066200 001 Motor with flange axis 5 3HAC061938 001 Timing belt axis 5 3HAC069061 001 Wrist cover Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 607 Standard toolkit Continues on next page Product manual IRB 1100 439 3HAC064992 001 Revision C Copyright 20...

Page 440: ...e calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior...

Page 441: ... values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor Use these procedures to remove the axis 5 motor Preparations before removing the axis 5 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginn...

Page 442: ...R Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003315 Remove the wrist cover right one when facing the robot rear 2 Disconnecting the axis 5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 442 Product manual IRB 1100 3HAC064...

Page 443: ...e Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003290 Loosen the screws and move the motor slightly to slacken the timing belt 2 Continues on next page Product manual IRB 1100 443 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 5 Replacing the axis 5 motor Continued ...

Page 444: ... the motor Use these procedures to refit the axis 5 motor Refitting the axis 5 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Continues on next page 444 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 5 Replacing the axis 5 motor Continued ...

Page 445: ...ectors MP5 and MP6 accessible from wrist side 2 Screw M3x12 12 9 Gleitmo 603 Geomet 500 3 pcs xx1800003291 Refit the screws and washers Note Do not tighten the screws yet 3 xx1800003292 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 4 Continues on next page Product manual IRB 1100 445 3HAC064992 001 Revision C Copyright 20192020 ABB Al...

Page 446: ...al referenced force for new belt 19 4 21 2 N xx1900000027 Tightening torque 1 4 Nm xx1800003290 Secure the motor with the screws 7 Used belt 151 162 Hz Use an acoustic tensiometer to measure the tim ing belt tension 8 New belt 167 213 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 9 Continues on next page 446 Product manual IRB ...

Page 447: ...ect cable routing is highly important If the cables are routed and secured incorrectly the cables can be damaged 2 Insert the cabling and connectors into the wrist 3 Refitting the wrist cover Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the cover that has contacting area with the cable package 2 Continues on next page Product manual IRB 1100 ...

Page 448: ... incorrectly the cables can be damaged 1 Screw M3x8 12 9 Gleitmo 603 Geomet 500 4 pcs Refit the cover 2 Tightening torque 1 2 Nm xx1800002944 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 448 Product manual IRB 1100 3HAC064992 001 Revision C Co...

Page 449: ... Business Portal www mypo rtal abb com Note Article number Spare part 3HAC066201 001 Motor with flange axis 6 3HAC061939 001 Timing belt axis 6 3HAC069061 001 Wrist cover Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 607 Standard toolkit Continues on next page Product manual IRB 1100 449 3HAC064992 001 Revision C Copyright 2019202...

Page 450: ...e calibration menu on the FlexPendant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior...

Page 451: ... values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor Use these procedures to remove the axis 6 motor Preparations before removing the axis 6 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginn...

Page 452: ...tion DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002949 Remove the wrist covers from both sides 2 Disconnecting the axis 6 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 452 Product manual IRB 1100 3HAC064992 001 Re...

Page 453: ...re and air pressure are turned off 1 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 2 xx1800002996 Remove the screws and washers 3 Carefully lift out the motor 4 Continues on next page Product manual IRB 1100 453 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 6 Replacing the axis 6 motor Continued ...

Page 454: ... 1 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003023 Orient the motor correctly and fit it into the lower arm Tip Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side 2 Continues on next page 454 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20...

Page 455: ...nger adjustment screw to the motor Note Do not insert the entire screw to the hole 5 Initial referenced force for used belt 8 96 9 8 N for reference only Use a handheld tensiometer hooking to the screw and pull the tensiometer to reach the initial refer enced force 6 Initial referenced force for new belt 12 8 14 xx1900000026 Continues on next page Product manual IRB 1100 455 3HAC064992 001 Revisio...

Page 456: ...ment loosen the motor screws and readjust 9 xx1900000007 Remove the adjustment screw from the motor 10 Reconnecting the axis 6 motor connectors Note Action xx1800002994 Reconnect the connectors FB6 MP6 Tip See the number markings on the connectors for help to find the corresponding connector 1 Continues on next page 456 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All r...

Page 457: ...se to the covers that have contacting area with the cable package 2 Screw M3x8 12 9 Gleitmo 603 Geomet 500 14 pcs Refit the wrist covers 3 Tightening torque 1 2 Nm xx1800002949 Refitting the process hub Note Action 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 1 Continues o...

Page 458: ...re Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 458 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 7 6 Replacing the axis 6 motor Continued ...

Page 459: ... via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC075521 001 Lower cable harness basic 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet 3HAC069062 001 Gear unit with pulley axis 1 3HAC069048 001 Base Continues on next page Product manual IRB 1100 459 3HAC064992 001 Revision C...

Page 460: ...toolkit on page 607 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot i The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for meas...

Page 461: ...ce values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on ...

Page 462: ...eguarded space 3 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002488 Remove the swing support cover 2 Continues on next page 462 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 463: ... the connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 5 xx1800002492 Remove the swing cover 6 Continues on next page Product manual IRB 1100 463 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Re...

Page 464: ...ly lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 10 Continues on next page ...

Page 465: ... cable package locking screw on the axis 1 gearbox from the swing and then loosen the locking screw 2 Remove the locking screw 3 Disconnecting the connectors at the division point Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 465 3HAC064992 001 Revision C Copyright 20192020 ABB...

Page 466: ...e female head of the connectors from the connector plate 3 Separating the cable package from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002499 Remove the cable bracket 2 Continues on next page 466 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 R...

Page 467: ... xx1800002501 Disconnect the connectors J2 C1 J2 C2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting Tip The connector clip has to be pressed 1 and pushed forward 2 to separate the J2 C2 for Ethernet cabling xx1800002943 3 Continues on next page Product manual IRB 1100 467 3HAC064992 001 Revision C Copyright 20192020 ABB All rig...

Page 468: ...on by removing the foundation attachment screws and put the robot on its side 4 Disconnecting the SMB cabling Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 2 Contin...

Page 469: ...x1800002468 Disconnect the connectors SMB P7 SMB J1 SMB J2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Remove the SMB cover completely from the base 5 Opening the connector interface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on ...

Page 470: ...e removed completely until the connectors are removed 2 xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 xx1800003056 Valid for cabling with bottom interface option 3309 1 Remove the base adapter 3 Continues on next page 470 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Contin...

Page 471: ...ulic pressure and air pressure are turned off 1 xx1800003035 Valid for cabling with rear interface Remove the base bottom cover 2 xx1800003057 Valid for cabling with bottom interface option 3309 1 Remove the base rear cover 3 xx1800003036 Disconnect the earth cable 4 Continues on next page Product manual IRB 1100 471 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8...

Page 472: ... position before disconnecting them to have as a reference when reconnecting 6 xx1800003039 Remove the female header of the J1M BR connect or from the connector plate 7 Continues on next page 472 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 473: ...turned off 1 xx1800003041 Disconnect the connectors FB1 MP1 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 2 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 473 3HAC...

Page 474: ...d air pressure are turned off 1 xx1800003043 Remove the pulley cover 2 Pulling out the cable package Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 474 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 475: ...the pulley cover from the lower cable package 4 Removing the axis 1 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 475 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 476: ... the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 4 Continues on next page 476 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 477: ... are turned off 1 xx1800003067 Remove the timing belt from its groove on the gearbox 2 Separating the base from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 477 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 g...

Page 478: ... have as a reference when refitting xx1800003068 2 xx1800003070 Separate the base from the swing CAUTION The axis 1 mechanical stop is accessible now Put it aside for later refitting xx1800003071 3 Continues on next page 478 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 479: ... hydraulic pressure and air pressure are turned off 1 xx1800003073 Remove the screws 2 xx1800003074 Pull out the gearbox 3 Continues on next page Product manual IRB 1100 479 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 480: ...wing casting 1 Screw M3x30 12 9 Gleitmo 603 Geomet 500 12 pcs Secure with screws 2 Tightening torque 1 6 Nm xx1800003073 Placing the axis 1 mechanical stop Note Action Mechanical stop axis 1 3HAC061947 001 Check the axis 1 mechanical stop Replace if damaged 1 Continues on next page 480 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Repla...

Page 481: ...e swing when putting xx1800003619 2 Refitting the base to the swing Note Action Screw M4x16 12 9 Gleitmo 603 Geomet 500 13 pcs Refit the base to the swing Note Pay attention to the screw and washer location xx1800003068 1 Tightening torque 4 4 Nm xx1800003069 Continues on next page Product manual IRB 1100 481 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Repla...

Page 482: ... all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003602 Check the cooling pad Replace if damaged 2 xx1800003085 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley 3 Continues on next page 482 Product manual IRB 1100 3HAC064992 001 Revision C ...

Page 483: ...or rectly in the groove of the pulley 4 Screw M4x16 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800003065 Adjusting the axis 1 timing belt tension Note Action xx1900000040 Use a handheld tensiometer hooking to the motor 1 Continues on next page Product manual IRB 1100 483 3HAC064992 001 Revision C Copyright 2019...

Page 484: ...ton Note Action brake release button assembly tool included in the special toolkit 3HAC071022 001 Tighten the brake release button using the tool 1 xx1800003040 Refitting the lower cable package through the axis 1 gearbox Notice that the procedure differs depending on if the connector interface is located either at the rear or at the bottom of the base Note Action xx1800003046 Refit the pulley cov...

Page 485: ...isted or strained Reroute if necessary 2 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page Product manual IRB 1100 485 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repai...

Page 486: ...es are twisted or strained Reroute if necessary 3 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page 486 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserve...

Page 487: ...ng screw hole on the gearbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 1 xx1800003049 xx1800003050 Continues on next page Product manual IRB 1100 487 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 488: ...quid after refitting Refitting the pulley cover Note Action Screw M3x8 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the puller cover 1 Tightening torque 1 2 Nm xx1800003043 Reconnecting the SMB cabling Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 46 1 Continues on next page 488 P...

Page 489: ...cables can be damaged 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 6 pcs Refit the SMB cover to the base 4 Tightening torque 1 2 Nm xx1800002467 Refitting the connector interface plate Note Action 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 1 Continues on next page Product ma...

Page 490: ...03 Geomet 500 6 pcs Refit the connector interface plate to the base 3 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page 490 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 491: ...he brake release cabling and axis 1 motor connectors Note Action xx1800003054 Reconnect the connectors J1M BR MP1 FB1 Tip See the number markings on the connectors for help to find the corresponding connector 1 Continues on next page Product manual IRB 1100 491 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 492: ... the base Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 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 3 Continues on next page 492 Product manual IRB 1100 3H...

Page 493: ...e foundation Note Action CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 1 Attachment screws M12x25 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 2 Washers 24 x 13 x 2 5 steel hard ness class 300HV Tightening Torque 50 Nm 5 Nm Continues on next page Product manual IRB 1...

Page 494: ...the same Y shaped connector 1 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for help to find the corresponding connector 2 Securing the cable package to the swing Note Action Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 1 Tightening torque 0 8 Nm xx1800002499 Continues on next page 494 Product manual IRB 1100 3HAC064992 001 ...

Page 495: ...ove the screws Replace with a new cooling pad and then refit the screws 3 Tightening torque 1 2 Nm xx1800003026 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 Continues on next page Product manual IRB 1100 4...

Page 496: ...iming belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 6 xx1900000010 Install an M6x25 or longer adjustment screw to the motor Note Do not insert the entire screw to the hole 7 Continues on next page 496 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 497: ...tening torque 3 5 Nm xx1800002493 Secure the motor with the screws 9 Used belt 163 174 Hz Use an acoustic tensiometer to measure the tim ing belt tension 10 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 11 Continues on next page Product manual IRB 1100 497 3HAC064992 001 Revision C Copyright 20192020 ABB All ri...

Page 498: ...r help to find the corresponding connector 13 Reconnecting the connectors at the division point Note Action xx1800003029 Insert the female header of the connectors to the connector plate 1 Continues on next page 498 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 499: ...rrectly the cables can be damaged 3 Screw M3x8 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 Continues on next page Product manual IRB 1100 499 3HAC064992 0...

Page 500: ...uding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 500 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 501: ...mber Spare part 3HAC073517 001 Gear unit with pulley axis 2 3HAC066144 001 Motor with flange axis 2 3HAC061935 001 Timing belt axis 2 3HAC069051 001 Swing cover 3HAC069052 001 Swing support cover Cooling pads are wear parts One cooling pad sheet contains 6 pieces of small pad Replace if damaged with one piece each time 3HAC071020 001 Cooling pad for axis 1 and 2 mo tors Continues on next page Prod...

Page 502: ...a is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Castrol Molub Alloy 777 1 NG Used to lubricate bearings on the swing support and lower arm support Grease Deciding calibration routine Decide which calibration routine to be used based on the information in the table Dependin...

Page 503: ...s to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the gearbox Use these procedures to remove the axis 2 gearbox Preparations before removing the axis 2 gearbox Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 xx1800003289 Jog the robot to the specified pos...

Page 504: ...re attached to the connector plate The connector plate cannot be removed completely until the connectors are re move from the plate 3 xx1800002490 Disconnect the connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 4 Continues on next page 504 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB ...

Page 505: ...P2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 7 xx1800002493 Loosen the screws and move the motor slightly to slacken the timing belt 8 Continues on next page Product manual IRB 1100 505 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 506: ...e of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 10 xx1800002496 Remove the timing belt from its groove on the motor 11 Separating the upper cable harness from the axis 2 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 5...

Page 507: ... a plastic hammer to knock on the swing support lightly CAUTION The support cannot be removed completely Make sure the hanging support will not wear or damage the cable harness 2 Separating the swing from the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 507 3HAC06499...

Page 508: ...g is hard to loosen from the housing use a plastic hammer to knock on the swing lightly 3 Removing the axis 2 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Move the lower arm aside a little to access the gearbox screws 2 xx1800003082 Remove the screws 3 Continues on next page 508 Product manual IRB 1100 3HAC064992 0...

Page 509: ... supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003084 Remove the cable block from the gearbox 2 Continues on next page Product manual IRB 1100 509 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 510: ...500 2 pcs Refit the cable block to the axis 2 gearbox 1 Tightening torque 0 6 Nm xx1800003084 Refitting the axis 2 gearbox Note Action xx1800003083 Refit the axis 2 gearbox 1 Continues on next page 510 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 511: ...ways use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 1 Tightening torque 4 4 Nm xx1900002203 Securing the swing support Note Action xx2000000058 Apply grease Castrol Molub Alloy 777 1 NG to the inner surface of the lower arm where contacts the bearing on the swing support 1 Continues on next page Product manual IRB 1100 511 3HAC064992 001 ...

Page 512: ... package to the axis 2 gearbox Note Action Screw M2 5x6 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 1 Tightening torque 0 6 Nm xx1800003002 Refitting the axis 2 motor Note Action Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 1 Continues on next page 512 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All right...

Page 513: ...he screws 3 Tightening torque 1 2 Nm xx1800003026 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 Continues on next page Product manual IRB 1100 513 3HAC064992 001 Revision C Copyright 20192020 ABB All rights...

Page 514: ...iming belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 6 xx1900000010 Install an M6x25 or longer adjustment screw to the motor Note Do not insert the entire screw to the hole 7 Continues on next page 514 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 515: ...tening torque 3 5 Nm xx1800002493 Secure the motor with the screws 9 Used belt 163 174 Hz Use an acoustic tensiometer to measure the tim ing belt tension 10 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 11 Continues on next page Product manual IRB 1100 515 3HAC064992 001 Revision C Copyright 20192020 ABB All ri...

Page 516: ... to the connector plate 1 xx1800002491 Reconnect the connector J2 FB2 Tip See the number markings on the connectors for help to find the corresponding connector 2 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 3 Continues on next page 516 Product manual IRB 1100 3HAC064992 0...

Page 517: ... cable package 2 Screw M3x8 12 9 Gleitmo 603 Geomet 500 Refit the covers Swing cover Swing support cover 3 Tightening torque 1 2 Nm xx1800003607 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 1100 517 3HAC064992 001 Revision C...

Page 518: ...00 via myABB Business Portal www mypo rtal abb com Note Article number Spare part 3HAC073518 001 Gear unit with pulley axis 3 3HAC073218 001 Labyrinth sealing ring 3HAC066183 001 Motor with flange axis 3 3HAC061936 001 Timing belt axis 3 3HAC069057 001 Lower arm cover 3HAC069059 001 Lower arm support cover Continues on next page 518 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192...

Page 519: ...24 VDC power supply Used for measuring the timing belt tension Acoustic tensiometer Used for measuring the timing belt tension Tensiometer i The robot is calibrated by either manual calibration or Axis Calibration at factory Always use the same calibration method as used at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the Fl...

Page 520: ...rence values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 570 If no previous reference values exist and no new reference values can be created then reference calibration is not possible ...

Page 521: ... pressure are turned off 1 xx1800003003 Remove the lower arm support cover 2 xx1800003004 Remove the connector plate CAUTION Be aware of the cablings that are attached to the connector plate The connector plate cannot be removed completely until the connectors are re move from the plate as shown in following step 3 Continues on next page Product manual IRB 1100 521 3HAC064992 001 Revision C Copyri...

Page 522: ...es for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003286 Loosen the lower arm support screws Tip If the lower arm support is hard to loosen from the housing use a plastic hammer to knock on the lower arm support lightly CAUTION The support cannot be removed completely Make sure the hanging support will not wear or damage the cable harness 2 Continues on next page 5...

Page 523: ...ve the lower arm cover 2 xx1800003008 Loosen the screws and move the motor slightly to slacken the timing belt 3 xx1800003022 Remove the timing belt from its grooves on the motor and gearbox 4 Continues on next page Product manual IRB 1100 523 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 524: ...obot at delivery Contact ABB for more informa tion 2 xx1800003090 Separate the lower arm from the housing Tip If the lower arm is hard to loosen from the hous ing use a plastic hammer to knock on the lower arm lightly 3 Removing the axis 3 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 524 Prod...

Page 525: ... xx1900001417 Remove the labyrinth sealing ring lightly and evenly 3 xx1800003284 Remove the screws 4 Continues on next page Product manual IRB 1100 525 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 526: ... gearbox Note Action xx1800003285 Refit the axis 3 gearbox 1 Screw M3x30 12 9 Gleitmo 603 Geomet 500 12 pcs Secure with screws 2 Tightening torque 1 8 Nm xx1800003284 Continues on next page 526 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 527: ...fitted to the axis 3 gearbox without any deflection 4 Screw M3x4 2 pcs Apply a little Loctite 243 to the screws and secure the labyrinth sealing ring with the screws 5 Tightening torque 0 8 Nm xx1900001425 Continues on next page Product manual IRB 1100 527 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 528: ...900002190 Securing the lower arm support Note Action xx2000000059 Apply grease Castrol Molub Alloy 777 1 NG to the inner surface of the housing where contacts the bearing on the lower arm support 1 Screw M5x16 12 9 Steel Black Oxide 5 pcs Refit the lower arm support 2 Tightening torque 8 Nm xx1800003088 Route the cable package through the lower arm support 3 Continues on next page 528 Product manu...

Page 529: ...ly in the grooves of the pul leys 1 xx1900000009 Install an M4x25 or longer adjustment screw to the motor Note Do not insert the entire screw to the hole 2 Continues on next page Product manual IRB 1100 529 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 530: ... pcs Secure the motor with the screws 4 Washer 3HAC063985 001 3 pcs Tightening torque 3 Nm xx1800003008 Used belt 102 109 Hz Use an acoustic tensiometer to measure the tim ing belt tension 5 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 6 Continues on next page 530 Product manual IRB 1100 3HAC064992 001 Revisio...

Page 531: ...e corresponding connector 1 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 2 Screw M2 5x6 12 9 Gleitmo 603 Geomet 500 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Continues on next page Product manual IRB 1100 531 3HAC064992 001 Revision C Copyright ...

Page 532: ...cable package 2 Screw M3x8 12 9 Gleitmo 603 Geomet 500 Refit the covers Lower arm cover Lower arm support cover 3 Tightening torque 1 2 Nm xx1800003608 Concluding procedure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 532 Product manual IRB 1100 3HAC064992 001 Rev...

Page 533: ...le number Spare part 3HAC069094 001 Process hub basic 3HAC069095 001 Process hub CP CS and air hose without Ethernet 3HAC069096 001 Process hub CP CS and air hose with Ethernet 3HAC073519 001 Gear unit with pulley axis 4 3HAC066184 001 Motor with flange axis 4 3HAC061937 001 Timing belt axis 4 3HAC066201 001 Motor with flange axis 6 3HAC061939 001 Timing belt axis 6 Continues on next page Product ...

Page 534: ...kit 3HAC071022 001 M3x25 eye bolt Used for measuring the timing belt tension Tensiometer Included in the special toolkit 3HAC071022 001 Used to remove and refit the J5 C2 connector if the Ethernet cabling is equipped J5 C2 connector assembly tool Included in the special toolkit 3HAC071022 001 Used to refit the axis 4 motor axis 4 motor fitting tool i The robot is calibrated by either manual calibr...

Page 535: ...rence values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 570 If no previous reference values exist and no new reference values can be created then reference calibration is not possible ...

Page 536: ...ir pressure are turned off 1 xx1800002944 Remove the screws and carefully open the cover CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors are disconnected as shown in following steps 2 xx1800002945 Disconnect the air hoses 3 Continues on next page 536 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB A...

Page 537: ...C1 5 J5 C2 connector assembly tool xx1800002948 For robots with Ethernet cabling Disconnect the connector J5 C2 using the tool 6 Removing the wrist covers Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 537 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Re...

Page 538: ...al power hydraulic pressure and air pressure are turned off 1 xx1800002950 Access the connector FB5 from the process hub and disconnect the connector 2 xx1800002993 Disconnect the connector MP5 3 Continues on next page 538 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 539: ... 2 Removing the axis 6 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 2 Continues on next page Product manual IRB 1100 539 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbo...

Page 540: ...ke sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003031 Valid for IRB 1100 4 0 475 Access the cable package locking screw on the axis 4 gearbox from the wrist and then loosen the locking screw 2 Continues on next page 540 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the...

Page 541: ... screw 3 xx1800003001 Disconnecting the axis 4 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003011 Remove the housing cover 2 Continues on next page Product manual IRB 1100 541 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 542: ...r cable harness from the housing 2 Removing the axis 4 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003094 Loosen the screws and move the motor slightly to slacken the timing belt 2 Continues on next page 542 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5...

Page 543: ...g Pay attention not to scratch the casting or damage the pad 4 xx1800003096 Remove the timing belt from its groove on the motor 5 Removing the pulley cover and axis 4 timing belt Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 543 3HAC064992 001 Revision C Copyright 20192020 ABB ...

Page 544: ... air pressure are turned off 1 xx1900002191 Remove the screws Note Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 2 Continues on next page 544 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Repl...

Page 545: ...m the housing 4 Removing the axis 4 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003300 Remove the screws 2 Continues on next page Product manual IRB 1100 545 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 546: ...n xx1800003310 Pull out the gearbox 3 Continues on next page 546 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 547: ...e sure the locking screw holes on the gearbox and extender unit or wrist are aligned with each other 1 Valid for IRB 1100 4 0 475 xx1800003313 Valid for IRB 1100 4 0 58 xx1800003312 Continues on next page Product manual IRB 1100 547 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 548: ...Action xx1800003075 Valid for IRB 1100 4 0 475 Refit the the wrist to the housing 1 xx1800003100 Valid for IRB 1100 4 0 58 Refit the extender unit and wrist to the housing 2 Continues on next page 548 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 549: ...xx1900002191 Refitting the axis 4 timing belt and pulley cover Note Action xx1800003098 Install the timing belt to the gearbox pulley and verify that the belt runs correctly in the groove of the pulley 1 Screw M3x8 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the pulley cover 2 Tightening torque 1 2 Nm xx1800003097 Continues on next page Product manual IRB 1100 549 3HAC064992 001 Revision C Copyright 2...

Page 550: ...C071021 001 xx1800003605 Check the cooling pad Replace if damaged 2 axis 4 motor fitting tool included in the special toolkit 3HAC071022 001 Use the motor fitting tool to fix the timing belt 3 xx1900000044 Continues on next page 550 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 551: ...on the timing belt 4 xx1800003617 Install the timing belt to the motor pulley 5 Screw M3x12 12 9 Gleitmo 603 Geomet 500 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC064765 001 3 pcs xx1800003095 Remove the motor fitting tool 7 Continues on next page Product manual IRB 1100 551 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 ...

Page 552: ... housing 1 xx1900000037 Fit an M3x25 eye bolt o the screw hole 2 xx1900000038 Use a handheld tensiometer hooking to the eye bolt 3 Continues on next page 552 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 553: ... 31 5 N xx1900000039 Tightening torque 1 4 Nm xx1800003094 Secure the motor with the screws 5 Plug screw 3HAC064146 001 Remove eye bolt and refit the screw and washer below the housing 6 Tightening torque 2 Nm Continues on next page Product manual IRB 1100 553 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 554: ... the locking screw hole B on the gearbox xx1800003017 Insert the cable package in the housing and through the axis 4 gearbox Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 1 xx1800003601 Continues on next page 554 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repai...

Page 555: ...crew hole on the gearbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 1 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page Product manual IRB 1100 555 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 ...

Page 556: ...id residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for IRB 1100 4 0 58 xx1800003001 Plug screw 3HAC064146 001 Valid for IRB 1100 4 0 58 3 Tightening torque 2 Nm xx1800003000 Refit the plug screw and washer on the extender unit Continues on next page 556 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB...

Page 557: ... on the connectors for help to find the corresponding connector 2 Refitting the housing cover Note Action Apply grease to the cable package cover all moving area of the package 1 Apply grease to the covers that have contacting area with the cable package 2 Continues on next page Product manual IRB 1100 557 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacin...

Page 558: ...edure Note Action Calibration is detailed in section Calibration on page 559 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 558 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 559: ...eneric term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can later on be used to re calibrate the robot back to the same po...

Page 560: ...n printed on its name plate To regain 100 Absolute accuracy perform ance the robot must be recalibrated for abso lute accuracy after repair or maintenance that affects the mechanical structure Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 1100 and is the most accurate method for the standard calibration It ...

Page 561: ...after replacements that do not include taking apart the robot structure standard calibration is sufficient The Absolute Accuracy option varies according to the robot mounting position This is printed on the robot name plate for each robot The robot must be in the correct mounting position when it is recalibrated for absolute accuracy References Article numbers for the calibration tools are listed ...

Page 562: ...age 565 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are connected at the first installation The robot is rebuilt If the robot is rebuilt for example after a crash or when ...

Page 563: ...n marks IRB 1100 1 2 5 6 4 3 xx1800002455 CAUTION To calibrate the axis 6 the notch on the wrist must be aligned with the marked pin hole on the tool flange Before installing a tool on the tool flange make sure a visible mark has been made to the tool at the corresponding position Product manual IRB 1100 563 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 6 Calibration 6 2 1 S...

Page 564: ...n gears and so on 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 xx1800002456 564 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 6 Calibration 6 2 2 Calibration movement di...

Page 565: ...nter with the FlexPendant on page 568 When all axes are positioned update the revolution counter 3 Correct calibration position of axis 4 When jogging the manipulator to synchronization position it is extremely important to make sure that axis 4 is positioned correctly Axis 4 can be calibrated at the wrong turn resulting in an incorrect manipulator calibration Make sure axis 4 is positioned accord...

Page 566: ...ess twists towards right proceed to step 4 2 0 60 120 240 180 300 xx1800003318 Cable harness twisting towards left Jog the axis 4 anti clockwise with the operator facing the rear until the cable harness is in vertic al state 3 Continues on next page 566 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 6 Calibration 6 3 Updating revolution counters Contin...

Page 567: ...que 1 2 Nm xx1800003011 If the axis is rotated one or more turns from its calibration position before updating the revolution counter the correct calibration position will be lost due to non integer gear ratio At delivery the manipulator is in the correct position Do NOT rotate axis 4 at power up before the revolution counters are updated Continues on next page Product manual IRB 1100 567 3HAC0649...

Page 568: ...e 5 The calibration options are displayed Tap Revolution Counters 6 In the Selection column select the axes for which revolution counters need to be up dated Note A warning is displayed prompting you to check the cable harness status before pro ceeding with the revolution counter update for axis 4 See Correct calibration position of axis 4 on page 565 7 Tap Update A dialog box is displayed warning...

Page 569: ...mounting hole on the tool flange The Axis Calibration procedure described roughly 1 A removable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause s...

Page 570: ...calibration there must be reference values created before repair is made to the robot if values are not already available Creating new values requires possibility to move the robot The reference values contain positions of all axes torque of axes and technical data about the tool installed A benefit with reference calibration is that the current state of the robot is stored and not the state when ...

Page 571: ...ble shows the dependencies between the axes Requirements for axis positioning during calibration Axis to calibrate Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1 Required position of axis Axis 1 0 0 Axis 2 0 0 Axis 3 Axis 4 X Axis 5 Axis 6 Axis to be calibrated Unrestricted Axis is allowed to be jogged to other position than 0 degrees Axis must be put in position 0 degrees 0 Special requirement X How t...

Page 572: ...he tool box also includes a unique calibra tion pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibration i The robot is calibrated by either manual calibration or Axis Calibration at factory Always use the same calibration method as used at the factory Information about valid calibration method is found on the calibration la...

Page 573: ... Straightness within 0 005 mm xx1500000951 Outer diameter A Periodic check of the calibration tool for the tool flange 3HAC058238 001 If including the tool flange calibration tool in a local periodic check system the following measures should be checked Outer diameter within Ø5g5 mm Straightness within 0 005 mm Continues on next page Product manual IRB 1100 573 3HAC064992 001 Revision C Copyright ...

Page 574: ... xx1600001142 Outer diameter A 574 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 6 Calibration 6 4 2 Calibration tools for Axis Calibration Continued ...

Page 575: ... on each axis as follows If there is not enough space on an axis to install a fixed calibration pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure For axis 6 there is only one bushing the second calibration tool is installed at the mounting flange of the turning disk xx1800003320 Continues on next...

Page 576: ...rotective plug included a sealing in the bushing Replace damaged parts with new Note Article number Spare part Replace if damaged or missing 3HAC059556 001 Protective plug for bushing Continues on next page 576 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Continued ...

Page 577: ... if damaged or missing 3HAC061926 001 Calibration pin cover 6 mm Product manual IRB 1100 577 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Continued ...

Page 578: ...dant If no data is found related to standard calibration manual calibration is used as default Required consumables Note Article number Consumable Clean cloth Spare parts Note Article number Spare part Replace if damaged or missing 3HAC059556 001 Protective plug for bushing Replace if damaged or missing 3HAC061926 001 Calibration pin cover 6 mm Overview of the calibration procedure on the FlexPend...

Page 579: ...libration data is saved as last step of the calibration procedure Preparation prior to calibration The calibration procedure is described in the FlexPendant while conducting it Note Action DANGER While conducting the calibration the robot needs to be connected to power Make sure that the robot s working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibr...

Page 580: ...e all necessary calibration equipment is fitted for the axis to be calibrated A warning that performing fine calibration can change programmed robot positions is also dis played Tap Yes to proceed Tap No to cancel Select the check box for the current axis axes to be calibrated Note A warning is displayed prompting you to check the cable harness status before proceeding with the fine calibration fo...

Page 581: ...y page for the selected mechanical unit is displayed 4 Calibration method used at factory for each axis is shown as well as calibration method used dur ing last field calibration Tap Calibration Methods on the right pane 5 The calibration options are displayed Tap Calibration 6 The software will automatically call for the proced ure for the valid calibration method A dialog box is displayed queryi...

Page 582: ...ovement directions for all axes on page 564 Axis Calibration with SafeMove option To be able to run Axis Calibration SafeMove needs to be unsynchronized The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine When a warning m...

Page 583: ...d Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 2 Protective plug for bushing 3HAC059556 001 Product manual IRB 1100 583 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 6 Calibration 6 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 584: ...ration to save reference values for all axes that is to be replaced Make sure that the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset value...

Page 585: ... ie 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification position 11 Repeat the ma...

Page 586: ... program twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 563 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on one side of the base 586 Pr...

Page 587: ...ectly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action Tap Jog 1 From the Mechanical unit list select a mechanical unit 2 From the Motion mode section select an axis set that need to be jogged 3 For example to jog axis 2 select the axis set Axis 1 3 Follow the screen instruction on ...

Page 588: ...This page is intentionally left blank ...

Page 589: ... and correctly fitted 2 Replace one thing at a time 3 Do not replace units randomly 4 Make sure that there are no loose screws turnings or other unexpected parts remaining after work has been performed 5 When the work is completed verify that the safety functions are working as intended Keep a track of history Make a historical fault log to keep track of problems over time Consult those working wi...

Page 590: ...ilities between hardware and software options and their configuration The robot recently had a software upgrade Check connections software versions The robot has recently been moved from one site to another an already working robot 590 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 7 Troubleshooting 7 1 Introduction to troubleshooting Continued ...

Page 591: ... the oil spill is small this step is sufficient Wipe off the oil or grease see Cleaning the IRB 1100 on page 85 2 Monitor the robot over time to see if new oil or grease occurs Check the gearbox oil level 3 Robots performing certain ex tremely heavy duty work cycles may be fitted with vented oil plugs These are not fitted to normal duty robots but can be purchased from your local ABB representativ...

Page 592: ...sed by Worn bearings Contaminations have entered the bearing grooves Loss of lubrication in bearings Loose heat sinks fans or metal parts If the noise is emitted from a gearbox the following can also apply Overheating Recommended actions The following actions are recommended Information Action CAUTION Allow hot parts to cool down 1 Verify that the service is done according to the maintenance sched...

Page 593: ...t ive Too hot gearbox oil may be caused by Incorrect oil quality or level The robot work cycle runs a specific axis too hard Investigate whether it is possible to program small cooling periods into the application Overpressure created inside gearbox 8 Product manual IRB 1100 593 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 7 Troubleshooting 7 3 Mechanical noise or dissonanc...

Page 594: ...g equipment Possible causes The symptom can be caused by Faulty brake Faulty power supply to the brake Recommended actions The following actions are recommended Information Action Determine which motor s causes the robot to collapse 1 See the circuit diagram Check the brake power supply to the col lapsing motor during the Motors OFF state 2 If found faulty the motor must be replaced as a complete ...

Page 595: ... the country in which the robot and the control unit are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the robo...

Page 596: ...ronmental hazards Example application Material Serial measurement board Batteries Lithium Cables motors Copper Base swing lower arm extender unit wrist motors gearboxes SMB unit etc Steel Motors Neodymium Cables SMB unit gearboxes timing belt cooling pads connector kits etc Plastic rubber Gearboxes process hub etc Oil grease Base base adapter swing swing support lower arm lower arm support swing c...

Page 597: ...l and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing d...

Page 598: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed 598 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All ri...

Page 599: ...apter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 1100 599 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 9 Reference information 9 1 Introduction ...

Page 600: ...vices Coordinate systems and motion nomenclatures ISO 9787 2013 Manipulating industrial robots performance criteria and related test methods ISO 9283 1998 Classification of air cleanliness EN ISO 14644 1 2015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005...

Page 601: ...pects Principles for design EN 574 1996 A1 2008 UL ANSI and other standards Description Standard Safety requirements for industrial robots and robot systems ANSI RIA R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 1100 601 3HAC064992 001 Revision C Copyright 20192020 ABB All ri...

Page 602: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 602 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 9 Reference information 9 3 Unit conversion ...

Page 603: ...ld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions ...

Page 604: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 605: ...ening torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 1100 605 3HAC064992 001 Re...

Page 606: ...essory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The arm weighs 25 kg All lifting accessories used must be sized accord ingly 606 Product manual IRB 1100 3HAC064992 001 Revision C Copyright 20192020 ABB Al...

Page 607: ...red are the sum of the standard toolkit and any tools listed in the instruction Contents standard toolkit Rem Tool Qty Socket head cap 2 17 mm 1 Torque wrench 0 3 45 Nm 1 For securing robot to foundation Torque wrench 50 Nm 5 Nm 1 Ratchet head for torque wrench 1 2 1 Hex socket head cap no 2 5 socket 1 2 bit L 110 mm 1 Small screwdriver 1 T handle with ball head 1 Small cutting plier 1 Plastic mal...

Page 608: ...bot i The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 Acoustic tensiometer Used for measuring the timing belt tension Tensiometer Used for measuring the timing belt tension Special toolkit 3HAC071022 001 Includes J5 C2 connector assembly tool brake release button assembly tool axis 4 motor fitting tool and M3x25 eye bolt...

Page 609: ...iews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 1100 609 3HAC064992 001 Revision C Copyright 20192020 ABB All rights reserved 10 Spare parts 10 1 Spare part lists and illustrations ...

Page 610: ...This page is intentionally left blank ...

Page 611: ...ion jogging to 587 scales 563 calibration scales 563 CalibWare 560 carbon dioxide extinguisher 27 cleaning 85 climbing on robot 29 Cold environments 79 connecting the robot and controller cabling 74 copper disposal 596 D damaged bearings 592 dimensions robot 67 direction of axes 564 E environmental information 596 equipment robot 67 ESD damage elimination 46 sensitive equipment 46 expected life 84...

Page 612: ...verfilled gearbox 591 P pedestal installed on pedestal 26 personnel requirements 16 plastic disposal 596 positive directions axes 564 PPE 16 product standards 600 protection classes 40 protection type 40 protective equipment 16 protective wear 16 R regional regulations 26 release brakes 32 replacements report 103 replacing base 194 battery pack 97 cable package lower 152 upper 110 extender unit 35...

Page 613: ... mounting 60 swing replacing 235 symbols safety 17 synchronization position 565 sync marks 563 system integrator requirements 26 system parameter Gravity Alpha 61 Gravity Beta 60 T technical data robot 37 temperatures operation 39 storage 39 testing brakes 33 timing belts inspecting 91 torques on foundation 37 troubleshooting safety 34 turning radius 45 U updating revolution counters 565 users req...

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Page 616: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC064992 001 Rev C en Copyright 20192020 ABB All rights reserved Specifications subject to change without notice ...

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