ABB CRB 1100 Product Manual Download Page 30

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1.5 Safety during operation

Automatic operation

Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.

Unexpected movement of robot arm

WARNING

Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.

Product manual - CRB 1100

3HAC078007-001 Revision: J

1 Safety

1.5 Safety during operation

Summary of Contents for CRB 1100

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

Page 2: ...Trace back information Workspace 23B version a17 Checked in 2023 06 29 Skribenta version 5 5 019 ...

Page 3: ...Product manual CRB 1100 4 0 475 CRB 1100 4 0 58 OmniCore Document ID 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty 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 f...

Page 5: ...oning 50 3 2 Unpacking 50 3 2 1 Pre installation procedure 51 3 2 2 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 Orienting and securing the robot 58 3 3 3 Manually releasing the brakes 60 3 3 4 Setting the system parameters for an inverted or a tilted ro...

Page 6: ...tenance or repair 163 4 Maintenance 163 4 1 Introduction 164 4 2 Maintenance schedule and expected component life 164 4 2 1 Specification of maintenance intervals 165 4 2 2 Maintenance schedule 167 4 2 3 Expected component life 168 4 3 Cleaning activities 168 4 3 1 Cleaning the CRB 1100 169 4 4 Inspection activities 169 4 4 1 Inspecting the information labels 171 4 4 2 Inspecting the robot cabling...

Page 7: ... 5 Reference calibration 679 6 5 Calibrating with Wrist Optimization method 681 6 6 Verifying the calibration 682 6 7 Checking the synchronization position 683 7 Troubleshooting 683 7 1 Introduction to troubleshooting 685 7 2 Oil and grease stains on motors and gearboxes 686 7 3 Mechanical noise or dissonance 687 7 4 Manipulator collapses on power down 688 7 5 Motor temperature too high 689 7 6 Co...

Page 8: ...10 9 6 Standard toolkit 711 9 7 Special tools 713 10 Spare parts 713 10 1 Spare part lists and illustrations 715 Index 8 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved Table of contents ...

Page 9: ...ion It is the responsibility of the integrator to provide safety and user guides for the robot system Who should read this manual This manual is intended for installation personnel maintenance personnel repair personnel Prerequisites A maintenance repair installation craftsman working with an ABB robot must be trained by ABB and have the required knowledge of mechanical and electrical installation...

Page 10: ...he product manuals for the manipulators and the controllers Revisions Description Revision First edition A Published in release 21B The following updates are done in this revision Text regarding fastener quality is updated see Fastener quality on page 70 Text regarding diameter of air hoses is updated see Customer connections on page 91 Added delivery information about the attachment screws see At...

Page 11: ...ic solvent or similar to clean the lamp cover D Published in release 22B The following updates are done in this revision Updated the optional port from LAN port to MGMT port which is used to connect the cable from robot to controller for lead through functionality Added installation and configuration of the two button type lead through device Added a list of general software configuration procedur...

Page 12: ... in release 23B The following updates are done in this revision Added pin assignment on XG1 connector of SafetyIO based laser scanner Updated the logical expressions for SafeMove configuration using Visual SafeMove see Configuring pre logic on page 114 J 12 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved Overview of this manual Continued ...

Page 13: ...on Troubleshooting Decommissioning 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 sy...

Page 14: ...dling of the products The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 14 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved Product documentation Continued ...

Page 15: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 17 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 16: ...tion of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB Ltd and its entities are not liable for damage and or loss related to such security breache...

Page 17: ...t 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 as intended 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 supplies orig...

Page 18: ...uence 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 instructions 18 Product manual CRB 1100 3HAC078007 001 Revisio...

Page 19: ...d 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 situation which if not...

Page 20: ...d to indicate where to find additional information or how to do an operation in an easier way TIP 20 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 21: ...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 22: ...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 22 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 2 2 Safety...

Page 23: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual CRB 1100 23 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...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 24 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 25: ...1000001242 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 CRB 1100 25 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ...t 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 26 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 27: ...ctive stops and emergency stops are described in the product manual for the controller For more information see Product manual OmniCore C30 Product manual CRB 1100 27 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 28: ...ification of allergenic materials in the product if any Securing the robot to the foundation The robot must be properly fixed to its foundation support as described in the respective product manual When the robot is installed at a height hanging or other than mounted directly on the floor there will be additional hazards Electrical safety Incoming mains must be installed to fulfill national regula...

Page 29: ...tandards Other hazards The risk assessment should also consider other hazards arising from the application such as but not limited to Water Compressed air Hydraulics End effector hazards require particular attention for applications which involve close human collaboration with the robot Verify the safety functions Before the robot system is put into operation verify that the safety functions are w...

Page 30: ...ode to automatic and initiating automatic operation Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered 30 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 5 Safety during operation ...

Page 31: ...that protective gear like goggles and gloves are al ways worn When working with lubricants there is a risk of an allergic reac tion Allergic reaction Gearbox 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 M...

Page 32: ...fied amount de pends on drained volume Hazards related to batteries Under rated 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 electro...

Page 33: ...xis can be released manually by pushing a brake release button How to release the brakes is described in the section Manually releasing the brakes on page 58 Product manual CRB 1100 33 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 6 2 Emergency release of the robot axes ...

Page 34: ... 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 Note It is recommended to run the service routine BrakeCheck as part of the regular maintenance see the operating manual for the robot controller For robots with the option SafeMove the Cyclic Br...

Page 35: ...y time DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers A risk assessment must be done to address both robot and robot system specific hazards Related information See also the safety information related to installation operation maintenance and repair Product manual CRB 1100 35 3HAC078007 001 Revision J Copyright 2021...

Page 36: ...oning on page 699 If the robot is decommissioned for storage take extra precaution to reset safety devices to delivery status 36 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 1 Safety 1 8 Safety during decommissioning ...

Page 37: ... solution safety separation technology and speed control with safety laser scanner s and lead through programming with a lead through device CRB 1100 enables safe collaborative operations and harmless contacts between robot and the operator The robot has an open structure that is especially adapted for flexible use and can communicate extensively with external systems Product manual CRB 1100 37 3H...

Page 38: ...tion Any angle Floor mounted Any angle Wall mounted Any angle Suspended Any angle Table mounted Note The actual mounting angle must always be configured in the system parameters otherwise the performance and lifetime is affected See Setting the system parameters for an inverted or a tilted robot on page 60 Loads on foundation robot The illustration shows the directions of the robots stress forces ...

Page 39: ...ese forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Maximum load emergency stop Endurance load in operation Force 710N 420 N Force xy 210 510 N 210 380 N Force z 330 Nm 180 Nm Torque xy 140 N...

Page 40: ... delivery from ABB 0 1 500 mm Flatness of foundation surface The value for levelness aims at the circum stance of the anchoring points in the robot base In order to compensate for an uneven sur face the robot can be recalibrated during in stallation If resolver encoder calibration is changed this will influence the absolute ac curacy The value is recommended for optimal per formance 22 Hz Note It ...

Page 41: ...ge conditions for the robot Value Parameter 25 C 13 F Minimum ambient temperature 55 C 131 F Maximum ambient temperature 70 C 158 F Maximum ambient temperature less than 24 hrs 95 at constant temperature gaseous only Maximum ambient humidity Operating conditions robot The table shows the allowed operating conditions for the robot Value Parameter 5 Ci 41 F Minimum ambient temperature 45 C 113 F Max...

Page 42: ...tion Safety functions and safety related data Safety functions and safety related data for CRB 1100 rely on the controller and safety laser scanners Safety data for the controller is detailed in the product manual of the robot controller see References on page 10 Safety data for the safety laser scanners is detailed in the user manual from the vendor see Operating instructions microScan3 PROFINET ...

Page 43: ...2 17 B 135 135 158 C 173 64 78 158 57 57 xx2000002545 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C Continues on next page Product manual CRB 1100 43 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 2 Manipulator description 2 4 Dimensions ...

Page 44: ... 17 B 135 135 158 173 64 78 158 57 57 xx2000002546 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C 44 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 2 Manipulator description 2 4 Dimensions Continued ...

Page 45: ...st 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 CRB 1100 45 3HAC0780...

Page 46: ...enter 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 46 Product manual CRB 1100 3HAC078007 001 Revisio...

Page 47: ...yload and the positions of other axes Simulation in RobotStudio is recom mended 230 Axis 1 115 113 Axis 2 205 55 Axis 3 230 Axis 4 125 120 Axis 5 Default value 400 Axis 6 Maximum revolution value 242 The default working range for axis 6 can be exten ded by changing parameter values in the soft ware Product manual CRB 1100 47 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 2 M...

Page 48: ...roy sensitive electronics Safe handling Use one of the following alternatives Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly Use an ESD protective floor mat The mat must be grounded through a current limiting resistor Use a dissipative table mat The mat should provide a controlled discharge of static voltages and must be gro...

Page 49: ...Before any installation work is commenced all safety information must be 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 page17 before performing any installation work Note Always connect the CRB 1100 and the robot to protective earth ...

Page 50: ... to handle the weight of the robot as specified in Weight robot on page 38 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 41 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 41 7 Before taking the robot to its installation site make sure th...

Page 51: ...to tip over The transportation position is the most stable position Do not change the robot position before securing it to the foundation Transportation position This figure shows the robot in its transportation position CRB 1100 4 0 475 10 35 45 xx2100000153 Continues on next page Product manual CRB 1100 51 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and c...

Page 52: ... actual configurations and options for example DressPack WARNING The robot is likely to be mechanically unstable if not secured to the foundation 52 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 2 2 Risk of tipping stability Continued ...

Page 53: ... 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 xx2100000156 By side When the robot is inverted grasp the robot with one hand supporting at the housing and the other hand holding the base xx2100000157 Invented Continues on next page Product manual ...

Page 54: ...red 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 56 5 54 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 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 CRB 1100 55 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 1 2 Lifting and rotating a suspended mounted robot ...

Page 56: ...ounted robot Use this procedure to orient and secure the robot floor mounted Note Action Make sure the installation site for the robot con forms to the specifications in section Technical data on page 38 1 The hole configuration of the base is shown in the figure in Hole con figuration base on page 57 Prepare the installation site with attachment holes The foundation surface must be clean and un p...

Page 57: ...m 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 xx1800002448 Pr...

Page 58: ...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 59 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 59: ...to enable 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 internal electrical components 2 Use the brake releasing button as described in...

Page 60: ...ion 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 system parameter Gravity Beta must be redefined If the robot is mou...

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 CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 4 Setting the system parameters for an inverted or a tilted robot Continued ...

Page 63: ... mounting the robot on a wall the working range of axis 1 is limited These limitations are specified in the table Working range on page 47 Defining the system parameters in RobotWare The value of the system parameters that define the mounting angle must be redefined when changing the mounting angle of the robot The parameters belong to the type Robot in the topic Motion Continues on next page Prod...

Page 64: ... The system parameters are configured in RobotStudio or on the FlexPendant 64 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 4 Setting the system parameters for an inverted or a tilted robot Continued ...

Page 65: ...ps 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 See the product specification for the robot listed in References on page 10 Product manual...

Page 66: ...7 225 10 250 562 A 314 101 182 17 B 135 135 158 C 173 64 78 158 57 57 xx2000002545 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C Continues on next page 66 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 6 Fitting equipment on the robot robot dimensions ...

Page 67: ...rning radius R61 C Attachment holes and dimensions Extra loads can be mounted on robot Definitions of dimensions and masses are shown in the following figures The robot is supplied with holes for fitting extra equipment Continues on next page Product manual CRB 1100 67 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 6 Fitting equipment on ...

Page 68: ...3 x6 40 4x M5x10 4x M4x6 40 B C D 169 A 145 B xx1800002449 CRB 1100 4 0 58 CRB 1100 4 0 475 Pos 303 248 A 250 200 B Continues on next page 68 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 6 Fitting equipment on the robot robot dimensions Continued ...

Page 69: ...8 G 426 E F xx1800002450 Continues on next page Product manual CRB 1100 69 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 6 Fitting equipment on the robot robot dimensions Continued ...

Page 70: ... the tool at the corresponding position For details about the synchronization mark see Synchronization marks and synchronization position for axes on page 657 Fastener quality When fitting tools on the tool flange only use screws with quality 12 9 For other equipment use suitable screws and tightening torque for your application 70 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2...

Page 71: ...t to stretch or squeeze the device cabling when moving the robot with the lead through device especially to extreme positions Otherwise it will cause cabling damages Note Two types are available to the lead through device used with the CRB 1100 no button type and two button type The actual delivered device type varies according to the order time Unless otherwise stated the instructions of installi...

Page 72: ...lead through device is mounted to the device base and then to the robot tool flange through an adapter Customers can use an L shape adapter offered by ABB option 3314 1 or design adapters according to actual requirements During adapter design hole dimensions on the device base and robot tool flange shall be considered Continues on next page 72 Product manual CRB 1100 3HAC078007 001 Revision J Copy...

Page 73: ...ype 8 10 1 20 68 8 16 9 39 4 26 4 19 5 0 15 19 5 0 15 R3 R29 75 4 x M4 THRU 25 0 1 3 0 2 x 4 5 THRU 8 4 4 52 36 xx2200000767 For the hole dimensions on robot tool flange see Tool flange standard on page70 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 CRB 1100 via myABB Business Portal www abb com myABB Note Articl...

Page 74: ...hrough device Note Action Remove all tools from the mounting flange 1 Calibration is detailed in section Calibration on page 653 Jog the robot to the synchronization position 2 Refer to Preparing the adapter on page 72 Prepare the lead through device adapter 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 the adap...

Page 75: ...ion and tightening torque of screws fixing the adapter to the tool flange vary according to actual applications xx2100000281 Screw M3x8 12 9 Lafre 2C2B FC6 9 4 pcs Tightening torque 1 8 Nm xx2000002222 Installing the lead through device no button type Note Action Screw M4x16 12 9 Lafre 2C2B FC6 9 4 pcs Install the device base to the adaptor 1 Tightening torque 3 Nm xx2000002223 Continues on next p...

Page 76: ...evice 3 Installing the lead through device two button type Note Action Screw M4x16 12 9 Lafre 2C2B FC6 9 4 pcs Install the device base to the adaptor 1 Tightening torque 3 Nm xx2200000763 xx2200000764 Insert the lead through device to the base 2 Continues on next page 76 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3...

Page 77: ...le to the MGMT port Note Pins 3 and 4 of X19 connector are used for the lead through device connection while pins 1 and 2 are occupied by the CP CS cable for lamp unit 2 Configuring the lead through functionality The lead through functionality is predefined for robots that are delivered with the option 3313 1 Lead through Device ordered If the lead through option is newly ordered for an existing r...

Page 78: ...N Safety in the area that not in the scanning range must always be considered The system integrator shall assess the potential risks within this area and make sure that proper measures have been applied to reduce risks 275 xx2100000168 Laser scanner types The following laser scanner package options are available 1 PROFIsafe based laser scanner option 3051 1 PROFIsafe scanner 2 PROFIsafe based lase...

Page 79: ...he controller and Application manual Scalable I O The supported PROFINET and SafetyIO base laser scanners are SICK microScan 3 Core and SICK microScan 3 Pro respectively Detailed scanner model can be obtained on the scanner nameplate Other scanner types or models might not provide full functionality For more details about the safety laser scanners see Operating instructions microScan3 PROFINET and...

Page 80: ...ion 3051 3 with PLC connected OmniCore controller PLC Laser Scanner1 XF1 PROFIsafe XD1 white brown blue black 24V 0V WAN Laser Scanner2 XF1 XD1 brown blue black 24V 0V PROFIsafe PROFIsafe white xx2200000298 Continues on next page 80 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 8 Installation of laser scanner Cont...

Page 81: ...k 24V 0V PROFIsafe PROFIsafe white xx2300000227 1 SafetyIO based laser scanner option 3051 2 Power DSQC 1042 Laser Scanner XG1 XD1 white brown blue black 24V 0V X2 OmniCore controller X19 X1 xx2200000299 Continues on next page Product manual CRB 1100 81 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 8 Installation of laser scanner Continu...

Page 82: ...4V 0V xx2200000300 Note If there are additional scalable I O devices available install and configure the additional devices by following the detailed procedures in Application manual Scalable I O Continues on next page 82 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 3 8 Installation of laser scanner Continued ...

Page 83: ...3 Green OSSD pair 2 OSSD B 4 Pink Universal input 1 5 Yellow Universal input 2 6 Black Universal input 3 7 Grey Universal input 4 8 Red Universal input 5 9 Violet Universal input 6 10 Grey with pink Universal input 7 11 Red with blue Universal input 8 12 White with green Universal input 9 13 Brown with green Universal input 10 14 White with yellow Universal output 1 15 Yellow with brown Universal ...

Page 84: ...6 or later 1 Y N Y Configuration of two PROFIsafe based laser scanners RobotWare 7 6 or later and PLC acting as Master on page 129 Y RobotWare 7 6 or later 2 Y N Y Configuration of one PROFIsafe based laser scanner RobotWare 7 10 or later and OmniCore acting as Master on page 133 Y RobotWare 7 10 or later 1 Y N N Configuration of two PROFIsafe based laser scanners RobotWare 7 10 or later and OmniC...

Page 85: ...existing in the system See Connecting the laser scanner s on page 79 2 Configure the new laser scanner See Configuration of two PROFIsafe based laser scanners RobotWare 7 6 or later and PLC acting as Master on page129 or Configuration of two SafetyIO base laser scanners Robot Ware 7 6 or later on page 146 Adding a new laser scanner Note Applicable only when using PROFIsafe based laser scanners Con...

Page 86: ...cal stops on the manipulator Mechanical stops are and can be installed on the manipulator as limiting devices to ensure that the manipulator axis does not exceed the working range values set in the software parameters Note The mechanical stops are only installed as safety precaution to physically stop the robot from exceeding the working range set A collision with a mechanical stop always requires...

Page 87: ...f the CRB 1100 via myABB Business Portal www abb com myABB 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 277 Product manual CRB 1100 87 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation...

Page 88: ...fitted on the robot by the customer low voltage signals and high voltage power supply protective ground Customer cables The customer cables also handle databus communication The customer cables also include the air hose See the product manual for the controller see document number in References on page 10 The hose for compressed air is integrated with the manipu lator cable harness Air hoses Robot...

Page 89: ... Robot cable signals Article number Signal cable length 3HAC067446 001 Signal cable shielded 3 m 3HAC067446 002 Signal cable shielded 7 m 3HAC067446 003 Signal cable shielded 15 m Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Continues on next page Product manual CRB 1100 89 3HAC07...

Page 90: ... more I O connections and shall always be used properly in applications It is recommended to shield the free ends not in use Do not use other types of CP CS cables or use in an improper way otherwise the lamp unit will not work and other unknown faulty may be raised Customer cables Ethernet floor cable Article number Ethernet floor cable lengthi 3HAC077020 001 7 m with lead through device cabling ...

Page 91: ...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 4 wiresi Customer power signal R1 R2 C1 A 30 V 1 A or 1 Gbits s 8 wiresii Customer power signal or Ethernet R1 R2 C2 B Outer diameter of air hose 4 mm 4 Max 6 bar Air C i The connector has 12 pins Only pins 5 to 8 are available for use...

Page 92: ...ts Ethernet 3HAC067414 001 M12 Ethernet Cat5e Male angled connector 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 connec...

Page 93: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

Page 94: ...sed scenarios with a PLC acting as the master connected any supported RobotWare version For SafetyIO based scenarios Upload the template SafeMove configuration file using the SafeMove configurator app on FlexPend ant Configuration of SafeMove using Visual SafeMove in RobotStudio on page 114 Application manual Func tional safety and SafeMove For PROFIsafe based scenarios with the control ler acting...

Page 95: ...ndard industrial robots Some of them are listed in this section How to configure RobotWare is described in Operating manual Integrator s guide OmniCore SafeMove See Application manual Functional safety and SafeMove Product manual CRB 1100 95 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 7 1 Information about RobotWare and CRB 1100 ...

Page 96: ...orm the following procedure to install the Collaborative Speed Control add in 1 Start RobotStudio and open the Add Ins tab The Gallery window is displayed 2 In the displayed Gallery window use the Search function or Common tags to find the Collaborative Speed Control add in 3 Click the displayed add in icon 4 In the right pane click Add The package is automatically installed and listed in the Add ...

Page 97: ...ng the Collaborative Speed Control add in on page 96 Checking lead through status The lead through device is not configured by default Users can perform the following procedure to check the configuration status 1 In the FlexPandant on the status bar tap the QuickSet button The QuickSet window is displayed 2 Tap Lead through The Lead through Settings tab page is displayed 3 Check the lead through d...

Page 98: ...page of the FlexPendant 2 Tap Lead through Device 3 For robots installing with the Collaborative Speed Control add in in version 1 1 or later choose the lead through device type from the drop down list Tip You can click About the versions and refer to the pictures to figure out your device type 4 In the Installation page of the displayed window select the installation position of the lead through ...

Page 99: ...e device is in the correct direction The indicator on the lead through is in the correct relative position with the lamp unit on the process hub The following figure takes the configuration Up as an example No button type xx2100000173 The device details are as follows xx2200000597 Continues on next page Product manual CRB 1100 99 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserve...

Page 100: ...nding parameters according to actual requirements For robots operating in RobotWare version earlier than 7 7 the device offset and orientation are available to set For robots operating in RobotWare version 7 7 or later the device offset orientation tool load mass and mass center are available to set 7 Tap Apply Enabling lead through Use the following procedure to enable lead through 1 Make sure th...

Page 101: ...og in the QuickSet window 3 In the Lead through Mode section select a mode 4 If required in the Lead through lock section use the lock button next to a axis to lock it 5 Hold the handler of the lead through device and gently move the robot to the desired position The robot moves to the selected position If the Lead through lock option is selected the robot moves in such a way that the movement is ...

Page 102: ...ll the forces that are lower than the threshold will be filtered out Use the following procedure to set the force threshold 1 Tap Settings on the home page of the FlexPendant 2 Tap Lead through Device 3 Tap Force threshold on the left pane 4 In the displayed window drag the Force slider to define a response force to move the robot The default force threshold is 10 xx2100000176 5 Observe the forces...

Page 103: ...dant 2 Tap Lead through Device 3 Tap Configurable buttons on the left pane 4 Select desired function from the drop down list for the required button Add a move location a Move block will be added to Wizard app This is the default configuration for the flat button Linear Reorient the lead through mode will be changed between linear and reorient This is the default configuration for the raised butto...

Page 104: ...ncapsulations and zones The first time that the app is opened a default factory setting is loaded If a safety configuration is loaded this will be shown The tab Robot Encapsulation contains the configuration of the encapsulations of the robot itself The tab Tool Encapsulation contains the configuration of the encapsulations of the tools The tab Tool Data contains the configuration for the tools Th...

Page 105: ...The factory setting is an empty safety configuration A loaded configuration can be removed and the system is then reset to the factory setting Encapsulations The encapsulations are geometries that can be in the shape of a sphere capsule or lozenge A sphere or capsule encapsulation can be modified in dimension and position A lozenge capsule can be modified in dimension position and rotation xx22000...

Page 106: ...obal supervision functions are not connected to a specific safe zone or safe range They can be added modified and deactivated For more information about the global supervision functions see Application manual Functional safety and SafeMove Synchronization The Synchronization tab is used to manually set the current joint positions for the robot For more information about synchronization see Applica...

Page 107: ...borative If the app is not shown then review the system settings in RobotStudio Installation Manager and add the option The first time that the app is opened a default factory setting is loaded This contains only the manipulator with Cyclic Brake Check activated There are no encapsulations safe zones or tool data defined The factory setting can always be resumed if needed To continue and create a ...

Page 108: ...validate is described in Application manual Functional safety and SafeMove 6 Select Apply to controller to proceed The controller is automatically restarted when applying the configuration Modify a configuration Use the following procedure to modify a loaded configuration and apply it to the robot controller 1 Select Enable Edit Mode to edit the safety configuration 2 If no configuration is loaded...

Page 109: ... in Application manual Functional safety and SafeMove 8 Apply the configuration to the controller The controller is automatically restarted when applying the configuration Modify a safe zone Use the following procedure to modify a safe zone 1 Add a new safe zone or select an existing safe zone 2 Tap Safe Zones to open the attributes 3 Add modify or remove vertices as needed to create the desired s...

Page 110: ...category signal and any other available setting applicable for the function Tip The functionality is described in detail in Application manual Functional safety and SafeMove Continues on next page 110 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 7 4 1 The SafeMove configurator app on FlexPendant Continued ...

Page 111: ... supervision functions are not connected to a specific safe zone or safe range They can be added modified and deactivated Modify the Cyclic Brake Check settings The Cyclic Brake Check functionality is active by default It can be modified and deactivated xx2200000451 Continues on next page Product manual CRB 1100 111 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installati...

Page 112: ...for safety interlocking All global supervision functions All tools with corresponding supervision functions Note Depending on the combination of functions the validation procedures have to be modified for the specific configuration A more detailed description of validation of the safety configuration is found in Application manual Functional safety and SafeMove After safety configuration is valida...

Page 113: ... on the FlexPendant 1 Log in as a user with the grant Safety Services 2 In the Settings app select the Safety Controller and then Configuration 3 Select the check box Validated Setting the configuration to locked When the responsible safety user has approved the validation of the configuration the status of the configuration should be changed to Locked on the FlexPendant Running the robot in auto ...

Page 114: ...the robot controller Visual SafeMove works both with the real controller and the virtual controller For a virtual controller a RobotStudio station should be used which allows zones to be generated automatically When not running a RobotStudio station Online Monitor is used to visualize the robot Starting Visual SafeMove Action Start RobotStudio with a virtual controller with or without a station or...

Page 115: ...alid for scenarios with 1 PROFIsafe based laser scanner connected ISH_Activate_TSP ISH_Supervise_TSP NOT EDGE NOT WarningArea1 ISH_Delayed_TSP OR NOT ISH_Ena bler_Delay_TSP Valid for scenarios with 2 PROFIsafe based laser scanners connected ISH_Supervise_TSP NOT EDGE NOT WarningAreaSM ISH_Delayed_TSP OR NOT ISH_Enabler_Delay_TSP Valid for scenarios with 1 PROFIsafe based laser scanner connected IS...

Page 116: ...safe based laser scanners are connected ii Required only when two PROFIsafe based laser scanners are connected 5 Click Signals view in the Safe IO Configuration page and then click Global signals to expand the signal list 6 Click on the Create new signal row and create the following signals ISH_TFO_Active ISH_TSP_Active ISH_TSP_Viol ISH_SST_Active ISH_SST_Viol 7 Change the default value of followi...

Page 117: ...ect the Warning only no stop check box enable CBC for all the joints and set other cyclic brake check properties Value Parameter 48 Max CRC test interval h 6 Pre warning time h 2 Standstill tolerance 0 02 Supervision threshold Configuring the supervision functions 1 In the Visual SafeMove ribbon tab choose Create Safe Zone from the Safe Zone list 2 Set zone properties Value Parameter BASE Tool Spe...

Page 118: ...gory1Stop Stop category Violation action ISH_TSP_Viol Signal 250 000 Max speed mm s Settings Leave blank Min speed mm s 5 In the Visual SafeMove browser right click Stand Still Supervisions and choose Create Global Stand Still Supervision Value Parameter ISH_Supervise_SST Activation ISH_SST_Active Function active status Category0Stop Stop category Violation action ISH_SST_Viol Signal Enabled for a...

Page 119: ...st shows the configuration parameters They need to be correctly configured in the software tools to enable communication between the scanner PLC and OmniCore system After the robot system is set up the default IP address of the WAN port is automatically configured as 192 168 10 10 24 Make sure the scanner and PLC are also configured in the 192 168 10 XXX segment In RobotStudio open the configurati...

Page 120: ...56 byte DO as an example If the user expands both DI and DO to 256 byte the possible device mapping addresses for the ProtectingArea WarningArea ProtectingAreaSST WarningAreaTSP and SafetyCommunicationEnable signals in 8 byte SDI device slot should be 2048 2049 2050 2051 and 2052 respectively GSD file The GSD file GSDML V2 xx ABB Robotics OmniCore YYYYMMDD xml can be obtained from the RobotStudio ...

Page 121: ...that is set by the user Within in this field range the lamp unit still lights up yellow but Tool Speed Supervi sion TSP is enabled If the robot moves in the speed that is out of the defined range for TSP the motor is off Yellow 67 WarningAreaTSP B For details about TSP see Application manual Functional safety and SafeMove Within this field range the lamp unit turns to red and the robot movement sp...

Page 122: ...tion manual TIA Portal and SICK microScan3 Siemens PLC integration instruction manual SIMATIC Step 7 Following described roughly 1 Connect the laser scanner to the PLC and controller See the physical connection in Connecting the laser scanner s on page 79 2 Open configuration software tool Safety Designer 3 Set IP address and PROFINET name in Configuration Addressing The scanner IP address must be...

Page 123: ...eate variables Example addressi Type Name I3 0 Bool ProtectingTrigger I4 1 Bool WarningTrigger I3 2 Bool ProtectingSSTTrigger I3 3 Bool WarningTSPTrigger Q68 0 Bool ProtectingArea Q68 1 Bool WarningArea Q68 2 Bool ProtectingAreaSST Q68 3 Bool WarningAreaTSP Q68 4 Bool SafetyCommunicationEnable Q3 0 Bool ActivateScanner i I3 X and I4 X are the addresses of the laser scanner Q68 X is the address of ...

Page 124: ...ns Tool Speed Supervision TSP and Stand Still Supervision SST must be configured 11 Configure other functions 12 Load the configuration to the safety controller 13 Restart the robot controller Detailed configuration procedures are specified in Application manual Functional safety and SafeMove With FlexPendant 1 Log in the FlexPendant The user logging in must have access grants to lock safety contr...

Page 125: ...ing Tool in RobotStudio The following list shows the configuration parameters They need to be correctly configured in the software tools to enable communication between the scanner PLC and OmniCore system After the robot system is set up the default IP address of the WAN port is automatically configured as 192 168 10 10 24 Make sure the scanner and PLC are also configured in the 192 168 10 XXX seg...

Page 126: ...1 Description Lamp col or Device mapping default Field The warning area field defines the largest range but it shall be within the scanning range of the scanner Yellow 1 WarningArea A Within in this field range the lamp unit on the process hub lights up yellow and the robot movement speed reduces to a lower speed that is set by the user Within this field range the lamp unit turns to red and the ro...

Page 127: ...ce checkbox must be selected and choose Rx Process image 6 Bytes from the drop down list 7 Create monitoring cases and assign the fields that are to be monitored to each monitoring cases in Configuration Monitoring cases Configuring the PLC The safety PLC connecting to the laser scanner and controller must support PROFIsafe and can act as a master Before configuration make sure the PLC is loaded w...

Page 128: ...1 Log in the FlexPendant Make sure the user logged in have access grants to lock safety controller configurations safety services and software synchronization 2 Tap SafeMove on the home page 3 Tap Load in the pop up message box to confirm loading of template SafeMove configuration files The controller restarts 4 After the controller is restarted tap Settings on the home page 5 Tap Safety Controlle...

Page 129: ...ing Tool in RobotStudio The following list shows the configuration parameters They need to be correctly configured in the software tools to enable communication between the scanners PLC and OmniCore system After the robot system is set up the default IP address of the WAN port is automatically configured as 192 168 10 10 24 Make sure the scanners and PLC are also configured in the 192 168 10 XXX s...

Page 130: ...1 Description Lamp col or Device mapping default Field The warning area field defines the largest range but it shall be within the scanning range of the scanner Yellow 1 WarningArea A Within in this field range the lamp unit on the process hub lights up yellow and the robot movement speed reduces to a lower speed that is set by the user Within this field range the lamp unit turns to red and the ro...

Page 131: ...s of each scanner and configure basic settings for the inputs and outputs in Configuration Inputs and outputs The Use one input source checkbox must be selected and choose Rx Process image 6 Bytes from the drop down list 7 Create monitoring cases and assign the fields that are to be monitored to each monitoring cases in Configuration Monitoring cases Configuring the PLC The safety PLC connecting t...

Page 132: ...WarningTrigger1 Check the communication between the PLC and controller is well and activate the laser scanner set up the communication between the laser scanner PLC and OmniCore controller Configuring SafeMove To enable SafeMove perform the following procedure 1 Log in the FlexPendant Make sure the user logged in have access grants to lock safety controller configurations safety services and softw...

Page 133: ... displayed 3 In the Configuration tab page on the left pane of the window right click PROFINET under I O system and select Scan Network The connected laser scanner is displayed 4 Right click on the laser scanner and choose Add as The laser scanner is added under Controller in the Configuration tab page Note Two device names are displayed in the list by default You shall right click on the device n...

Page 134: ...ller 10 Restart the controller 11 After the controller is restarted check the laser scanner name in the RAPID program InternalSpeedHandling_User in task T_ROB1 and make sure it is consistent with the name that the user defines for the laser scanner If the names are inconsistent use the following steps to modify a In the Controller pane double click the RAPID program InternalSpeedHandling_User in t...

Page 135: ...ands still Red 0 ProtectingArea B Configuration procedure Before starting the configuration obtain the microScan 3 Core PROFINET GSDML file and the software tool Safety Designer from SICK s website first Make sure both the file and the software tool are in the latest versions Detailed procedures about how to configure the laser scanner are detailed in Operating instructions microScan3 PROFINET Fol...

Page 136: ...es and assign the fields that are to be monitored to each monitoring cases in Configuration Monitoring cases Configuring SafeMove To enable SafeMove perform the following procedure 1 Start RobotStudio and connect the controller The user account logging in the controller must be granted with the Safety Services permission The write access to the controller is requested 2 In the Controller tab click...

Page 137: ...displayed 3 In the Configuration tab page on the left pane of the window right click PROFINET under I O system and select Scan Network The connected laser scanners are displayed 4 Right click one of the laser scanners and choose Add as The laser scanner is added under Controller in the Configuration tab page Note Two device names are displayed in the list by default You shall right click on the de...

Page 138: ...Refer to the cut off setting defined in the Safety Designer software and enter the actual value 10 In the I O Engineering tab click Write Config to write the configurations to the controller 11 Restart the controller 12 After the controller is restarted check the laser scanner name in RAPID program InternalSpeedHandling_User in task T_ROB1 and make sure it is consistent with the name that the user...

Page 139: ... still Red 0 ProtectingArea B Configuration procedure Before starting the configuration obtain the microScan 3 Core PROFINET GSDML file and the software tool Safety Designer from SICK s website first Make sure both the file and the software tool are in the latest versions Detailed procedures about how to configure the laser scanner are detailed in Operating instructions microScan3 PROFINET Followi...

Page 140: ...oose Rx Process image 6 Bytes from the drop down list 7 Create monitoring cases and assign the fields that are to be monitored to each monitoring cases in Configuration Monitoring cases Configuring SafeMove To enable SafeMove perform the following procedure 1 Start RobotStudio and connect the controller The user account logging in the controller must be granted with the Safety Services permission ...

Page 141: ...ed Control add in on page 96 The I O configuration can be seen using I O Engineering Tool in RobotStudio The following table lists the device mapping information of Scalable_IO signals which are automatically configured after the add in installation Device Device mapping Signal name ABB_Scalable_IO 0 ABB_Scalable_IO_0_DI1i ABB_Scalable_IO 1 ABB_Scalable_IO_0_DI2i ABB_Scalable_IO 2 ABB_Scalable_IO_...

Page 142: ...d ProtectingArea B Configuration procedure Before starting the configuration obtain the software tool Safety Designer from SICK s website first Make sure the software tool is in the latest version Detailed procedures about how to configure the laser scanner are detailed in Operating instructions microScan3 Pro I O from the vendor Following described the procedure roughly 1 Open configuration softw...

Page 143: ...the devicei Pin in cable D101 Pin1 OSSD1A DI02 Pin2 OSSD1B DI03 Pin3 OSSD2A DI04 Pin4 OSSD2B Circuit of D101 D102 D103 and D104 Pin17 i For detailed information of pin definitions in connector X2 Digital inputs of the scalable I O device DSQC1042 see the product specification of the controller and Application manual Scalable I O Configuring the scalable I O device Detailed procedures about how to ...

Page 144: ...from the drop down list e Remove the texts in the Create new I O signals using name prefix text box and then click OK Information of two devices can be observed CabinetIO and ABB_Scalable_IO Communication status of ABB_Scalable_IO will turn to normal after the SafeMove template file is uploaded using the SafeMove configurator app Note The configuration could also be done using the I O application ...

Page 145: ...ntroller 6 Tap Synchronization in the left pane 7 Jog the robot to match the Actual Positions values with the Sync Positions values Make sure the values are the same 8 Tap Synchronize Product manual CRB 1100 145 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 7 5 6 Configuration of one SafetyIO base laser scanner RobotWare 7 6 or later Conti...

Page 146: ...lists the device mapping information of Scalable_IO signals which are automatically configured after the add in installation Device Device mapping Signal name ABB_Scalable_IO 0 ABB_Scalable_IO_0_DI1i ABB_Scalable_IO 1 ABB_Scalable_IO_0_DI2i ABB_Scalable_IO 2 ABB_Scalable_IO_0_DI3ii ABB_Scalable_IO 3 ABB_Scalable_IO_0_DI4ii ABB_Scalable_IO 4 ABB_Scalable_IO_0_DI5i ABB_Scalable_IO 5 ABB_Scalable_IO_...

Page 147: ...rotectingArea B Configuration procedure Before starting the configuration obtain the software tool Safety Designer from SICK s website first Make sure the software tool is in the latest version Detailed procedures about how to configure the laser scanners are detailed in Operating instructions microScan3 Pro I O from the vendor Following described the procedure roughly 1 Open configuration softwar...

Page 148: ... 17 8 Connect the laser scanners to safety module with the defined pins Pin position number in X2 connector of the devicei Pin in cable Scanner D101 Pin1 OSSD1A Scanner 1 DI02 Pin2 OSSD1B DI03 Pin3 OSSD2A DI04 Pin4 OSSD2B Circuit of D101 D102 D103 and D104 Pin17 D105 Pin1 OSSD1A Scanner 2 DI06 Pin2 OSSD1B DI07 Pin3 OSSD2A DI08 Pin4 OSSD2B Circuit of D105 D106 D107 and D108 Pin17 i For detailed inf...

Page 149: ...8 125 130 ABB_Scalable_IO Actual serial number of the device 192 168 125 131 ABB_Scalable_IO1 c Right click ABB_Scalable_IO1 and choose Configure from the shortcut menu d In the displayed dialog box choose the Configure as replacement device option and select ABB_Scalable_IO from the drop down list e Remove the texts in the Create new I O signals using name prefix text box and then click OK Inform...

Page 150: ...eMove configuration files The controller restarts 4 After the controller is restarted tap Settings on the home page 5 Tap Safety Controller 6 Tap Synchronization in the left pane 7 Jog the robot to match the Actual Positions values with the Sync Positions values Make sure the values are the same 8 Tap Synchronize 150 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rig...

Page 151: ...ection fields defined for laser scanner to monitor and perform different program execution actions may result in different movement speed This section describes the speed control strategies for typical scenarios Strategies RobotWare 7 5 Users in Protecting area xx2100000512 Continues on next page Product manual CRB 1100 151 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 In...

Page 152: ...triggered but SST TSP not configured xx2100000514 Continues on next page 152 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 7 5 8 Speed control strategies Continued ...

Page 153: ... in Protecting area xx2200000302 Users in Warning area xx2200000303 Product manual CRB 1100 153 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 7 5 8 Speed control strategies Continued ...

Page 154: ...es the lamp unit cabling connection between the manipulator base and controller with base I O module configured For more details about cabling see the circuit diagram of the manipulator C B A xx2100000291 R1 C1 connector on robot base A Pins GND DO1 DO2 and DO3 are occupied for lamp unit X1 connector of I O module on controller B Pins 1 and 2 are occupied for lamp unit X19 connector on controller ...

Page 155: ...For RobotWare 7 5 or earlier the manipulator will re duce to 0 speed and stands still For RobotWare 7 6 or later the speed shown on the FlexPendant remains but the manipulator will stand still Product manual CRB 1100 155 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 7 6 Robot status indication Continued ...

Page 156: ...icator colors RGB of the LED lamp is controlled by values defined in RAPID instruction SWIFTI_SetCustomizedLEDColor in routine SWIFTI_LedMain which can affect the color that the lamp shows The routine exists in the system module SWIFTI_Main of task T_SWIFTI_LED xx2200000434 The following table lists the logical value combinations and corresponding lamp colors Parameter value 3 Parameter value 2 Pa...

Page 157: ...igate to the function ISH_b_FunctionlityIsUsed and set its value from default TRUE to FALSE xx2200000435 3 Save the change and apply to the controller SafeMove configurations also affect the speed control on the robot to achieve further safety SafeMove is still functional after the SpeedHandling function in RAPID program is deactivated Use the following procedure to disable the speed control funct...

Page 158: ...area the robot speed is limited to 250 mm sec by default Use the following procedure to change the speed limit based on risk assessment of the final application 1 In RobotStudio open the RAPID program InternalSpeedHandling_User in task T_ROB1 2 Navigate to the function ISH_n_Speed_In_WarningArea_mm_s and set its value from default 250 to any required value xx2200000437 3 Save the change and apply ...

Page 159: ...afeMove Properties window set the Max speed mm s in the Speed limits area to a required value xx2200000439 6 Apply the configuration to the controller by clicking Write to Controller in the Controller group in the Configuration category Continues on next page Product manual CRB 1100 159 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 3 Installation and commissioning 3 7 7 Use...

Page 160: ...l_SST and ISH_AtUser_Period_ms_Until_TSP according to application requirements using the following procedure The change must be based on the risk assessment of the final application 1 Open the RobotStudio 2 Log in the controller using the Admin account and request the write access 3 In the Controller tab choose Visual SafeMove from the Safety group in the Configuration category 4 In the Visual Saf...

Page 161: ...quipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Verify that no personnel is leaning on or have their head or neck close to the robot 5 Verify that all arm covers and paddings if any are properly secured to the robot 6 If maintenance or repair has been done verify the ...

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Page 163: ... 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 17 before performing any service work The maintenance must be done by qualified personnel in accordance with the safety requirements set forth in the applicable national and reg...

Page 164: ...nning 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 th...

Page 165: ...ot cabling on page 171 x iv Inspecting the robot harness Lubricating the cable package on page 176 x v Lubricating the robot harness Replacing the battery pack on page 178 x vi Replacing the SMB battery pack Recommended to robots with the SafeMove option See Application manual Functional safety and SafeMove x viii Running the Cyclic Brake Check routinevii x Overhaul of complete robot i Regularly i...

Page 166: ...battery is to be replaced at given maintenance interval or at battery low alert vii Not needed separately if already included in the application viii Recommended test interval is within the range 8 48 hours 166 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 4 Maintenance 4 2 2 Maintenance schedule Continued ...

Page 167: ...normal usage 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 ...

Page 168: ... 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 remove any covers or other protective devices before cleaning the robot Cleaning methods This following table defines what cleaning methods are allowed for ABB manipulators depending on the...

Page 169: ...bel Brake release Read manual A xx2100000161 ABB logo also specifying robot type A Cobot label B Instruction label C Brake release UL label D Read manual label also specifying warning labels E Rating label CE label and AbsAcc label F Calibration label G Required tools and equipment Visual inspection no tools are required Continues on next page Product manual CRB 1100 169 3HAC078007 001 Revision J ...

Page 170: ...eguarded 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 713 Replace any missing or damaged labels 3 170 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 4 Maintenance 4 4 1 Inspecting the information labels Continued ...

Page 171: ...ion 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 the cabling to motors 1 and 2 Look for abrasions cuts or crush damage 2 Replace the cabling if wear or damage is detected 3 Product manual CRB 1100 171 3...

Page 172: ...e timing belts are located as shown in the figures Location Axis xx1800002457 1 xx1800002458 2 Continues on next page 172 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 4 Maintenance 4 4 3 Inspecting timing belts ...

Page 173: ... Axis xx1800002459 3 xx1800002460 4 Continues on next page Product manual CRB 1100 173 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 4 Maintenance 4 4 3 Inspecting timing belts Continued ...

Page 174: ...olkit on page 710 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 174 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 4 Maintenance 4 4 3 Inspecting timing belts Continued ...

Page 175: ...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 176: ...ndard 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 pre...

Page 177: ...cable package on page 235 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 Product manual CRB 1100 177 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 4 Maintenance 4 5 1 Lubricating the cable package Continued ...

Page 178: ... be out of date See the latest spare parts of the CRB 1100 via myABB Business Portal www abb com myABB 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 178 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 4 Ma...

Page 179: ...ibra tion Used to release the motor brakes 24 VDC power supply Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Removing the battery pack Use these procedures to remove the battery pack Preparations before removing the battery pack Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 ...

Page 180: ...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 181: ...GE 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 48 2 xx1800002469 Disconnect the battery cable 3 xx1800002470 Remove the battery pack by cutting the cable strap 4 Continues on next page Product manual CRB 1100 181 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 4 Maintenance 4 6 1 Replaci...

Page 182: ...0002470 Secure the battery pack using the cable strap 2 xx1800002469 Reconnect the battery cable 3 Reconnecting the SMB connectors 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 48 1 Continues on next page 182 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 20...

Page 183: ...an be damaged 3 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 Produ...

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Page 185: ... article number and the revision of both the replaced unit and the replacement 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 17 before commencing any service work Note If the CRB 1100 is connected to power always make sure that the CRB 1100 is connected to protect...

Page 186: ...ealing in its original wrappings or protect it 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 Radial sealings A radial sealing consists of a flexible rubber lip bonded to a rigid metal case Only one side of the sealing is static wit...

Page 187: ... foreign particles adhering to the sealing 3 A B C xx2000000071 A Main lip B Grease C Dust lip Fill 2 3 of the 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 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 Con...

Page 188: ...venly 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 and mating surfaces 3 They should be free of pores contamination and ...

Page 189: ...t Knife Lint free cloth Removing Description Action xx2300000950 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 Product manual CRB 1100 189 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 2 2 Cut the p...

Page 190: ...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 190 Product manual CRB 1100 3HAC...

Page 191: ...1100 4 0 475 3HAC060419 003 Upper cable harness CP CS and air hose with Ethernet Used with CRB 1100 4 0 58 3HAC060416 003 Extension upper cable harness CP CS and air hose with Ethernet 3HAC077335 001 Process hub with lamp unit CP CS and air hose with Ethernet 3HAC076495 001 Multi color lamp unit 14 mm 3HAC075972 001 Lamp unit cover 3HAC083588 001 Motor with flange axis 2 3HAC061935 001 Timing belt...

Page 192: ...ors 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 710 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for CRB 1100 to be f...

Page 193: ...om 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 proced ure is completed for calibration of the ro bot Creating new values requires possib...

Page 194: ...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 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002488 Remove the swing support cover 3 Continues on next page 194 Product manual CRB 110...

Page 195: ...e connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 6 xx1800002492 Remove the swing cover 7 Continues on next page Product manual CRB 1100 195 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repa...

Page 196: ... 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 11 xx1800003603 CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step Continues on next page 19...

Page 197: ...00002497 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 CRB 1100 197 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5...

Page 198: ...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 198 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upp...

Page 199: ...Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2000002219 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 Product manual CRB 1100 19...

Page 200: ...100000293 For robots with CP CS cabling Disconnect the connector J5 C1 5 J5 C2 connector assembly tool For robots with Ethernet cabling 6 xx1800002948 Disconnect the connector J5 C2 using the tool Continues on next page 200 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 201: ...nit 2 Removing the wrist covers Note Action 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 Continues on next page Product manual CRB 1100 201 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 202: ...ub and disconnect the connector 2 xx1800002993 Disconnect the connector MP5 3 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 202 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cab...

Page 203: ... 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 3 Continues on next page Product manual CRB 1100 203 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Con...

Page 204: ...sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003031 Valid for CRB 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 204 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the u...

Page 205: ...1800003001 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 CRB 1100 205 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package...

Page 206: ...e 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 206 Product manual CRB 1100 3...

Page 207: ...sure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800003007 Remove the lower arm cover 3 Continues on next page Product manual CRB 1100 207 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 208: ...ON 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 6 xx1800003604 Continues on next page 208 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continue...

Page 209: ...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 CRB 1100 209 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 210: ...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 210 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 211: ...able harness from the robot in the direction shown in the figure 2 Continues on next page Product manual CRB 1100 211 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 212: ...ch should be at the opposite direction to the locking screw hole B on the gearbox Insert the cable package in the housing and through the axis 4 gearbox Tip Wrap the connectors with the masking tape 1 xx1800003017 CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary xx1800003601 Continues on next page 212 Product manual CRB 1100 3HAC078007 001 Revision J Copyright...

Page 213: ... 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 xx1800003018 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page Product manual CRB 1100 213 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cab...

Page 214: ...residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for CRB 1100 4 0 58 xx1800003001 Plug screw 3HAC064146 001 Valid for CRB 1100 4 0 58 3 Tightening torque 2 Nm Refit the plug screw and washer on the extender unit xx1800003000 Continues on next page 214 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB A...

Page 215: ...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 CRB 1100 215 3HAC078007 001 Revision J Copyright 2021 2023 ABB All ri...

Page 216: ... 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 216 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 217: ... 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 Check the cooling pad Replace if damaged 2 xx1800003604 Continues on next page Product manual CRB 1100 217 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserve...

Page 218: ...FC6 9 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 218 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper ...

Page 219: ... 94 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 7 Initial referenced force for new belt 31 34 2 N xx1900000028 Continues on next page Product manual CRB 1100 219 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 220: ... 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 220 Product manual CRB 1100 3HAC078007 001 Revision J Copyright...

Page 221: ...crew M2 5x6 12 9 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Screw M3x12 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 4 Tightening torque 0 4 Nm xx1800003004 Continues on next page Product manual CRB 1100 221 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 222: ...undamaged 1 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector 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 xx1800003023 Continues on next page 222 Product manual CRB 1100 3HAC078007 001 Revision J Cop...

Page 223: ...justment 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 dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 6 Initial referenced force for new belt 12 8 14 xx1900000026 Continues on next page Product manual CRB 1100 223 3HAC078007 001 Revision J Cop...

Page 224: ...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 224 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All right...

Page 225: ...ding 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 lamp unit Notice that the procedure is valid only when the lamp unit needs a replacement Note Action Multi color lamp unit 14 mm 3HAC076495 001 ...

Page 226: ...ct ors 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 shaped connector 2 xx2100000293 For robots with CP CS cabling Reconnect the connector J5 C1 3 Continues on next page 226 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 20...

Page 227: ...B FC6 9 4 pcs Refit the cover 6 Tightening torque 1 2 Nm xx2000002219 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 connect...

Page 228: ... M3x8 12 9 Lafre 2C2B FC6 9 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 228 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable pac...

Page 229: ...ews 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 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 xx1800003027 Continues on next page Product manual CRB 1100 229 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights rese...

Page 230: ...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 230 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 231: ...ening torque 3 5 Nm Secure the motor with the screws 9 xx1800002493 Used belt 163 174 Hz Use a sonic tension meter to measure the timing 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 CRB 1100 231 3HAC078007 001 Revision J Copyright 2021 2023 ABB All right...

Page 232: ...elp 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 232 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 233: ...ncorrectly the cables can be damaged 3 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 Product manual CRB 1100 233 3HAC078007 001 Revisi...

Page 234: ...procedure Note Action Calibration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 234 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable pack...

Page 235: ...wer cable harness CP CS and air hose with Ethernet 3HAC083588 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 001 Base rear cover Used for robots with bottom con nector interface 3HAC070313 001 Base adapter 3HAC069051 001 ...

Page 236: ...a unique calibration pin for CRB 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 Sonic tension meter Used for measuring the timing belt tension Dynamometer Included in the special toolkit 3HAC071022 001 Used to remove and refit the ...

Page 237: ...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 664 If no previous reference values exist and no new reference val...

Page 238: ... axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002488 Remove the swing support cover 3 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 4 Continues on next page 238 Product manual...

Page 239: ...ad of the connector from the connector plate 6 xx1800002492 Remove the swing cover 7 xx1800002495 Disconnect the connector MP2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 8 Continues on next page Product manual CRB 1100 239 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lo...

Page 240: ... caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 11 xx1800003603 CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step xx1800002496 Remove the timing belt from its groove on the motor 12 Continues on next page 240 Product manual CRB 1100 3HAC078007 001 Revisio...

Page 241: ...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 Product manual CRB 1100 24...

Page 242: ...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 242 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 ...

Page 243: ...ip 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 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 CRB 1100 243 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Re...

Page 244: ...pletely 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 pre...

Page 245: ...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 Product manual CRB 1100 245 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 246: ...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 246 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Con...

Page 247: ...c 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 CRB 1100 247 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2...

Page 248: ...sition 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 CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 249: ...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 Product manual CRB 1100 249 3HAC078...

Page 250: ...ir 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 CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 251: ... 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 Product manual CRB 1100 251 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 252: ...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 252 Product manual CRB 1100 3HAC078007 001 Revision J Copyright ...

Page 253: ...ed 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 CRB 1100 253 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair ...

Page 254: ...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 254 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved ...

Page 255: ...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 CRB 1100 255 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 256: ...uid after refitting Refitting the pulley cover Note Action Screw M3x8 12 9 Lafre 2C2B FC6 9 3 pcs Refit the puller cover 1 Tightening torque 1 2 Nm xx1800003043 Reconnecting the SMB connectors 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 48 1 Continues on next page 256 Produ...

Page 257: ...cables can be damaged 3 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 manual C...

Page 258: ...B FC6 9 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 258 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 259: ...uring 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 Product manual CRB 1100 259 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 260: ...for help to find the corresponding connector 1 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Reconnect the floor cable together with the con nector plate 2 Tightening torque 0 8 Nm xx1800003037 xx1800003036 Continues on next page 260 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 261: ...rect 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 Lafre 2C2B FC6 9 6 pcs Valid for cabling with bottom interface option 3309 1 5 Tightening torque 1 2 Nm Refit the rear cover xx180000305...

Page 262: ...ernet 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 help to find ...

Page 263: ... 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 Check the cooling pad Replace if damaged as shown in the following step 2 xx1800003603 Continues on next page Product manual CRB 1100 263 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Con...

Page 264: ...on nector Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 xx1800003027 Screw M4x16 12 9 Lafre 2C2B FC6 9 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 264 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights ...

Page 265: ... to the hole 7 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 8 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page Product manual CRB 1100 265 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2...

Page 266: ...s 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 266 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 2 Re...

Page 267: ...responding 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 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Continues on next page Product manual CRB 1100 267 3HAC078007 001 Revision J Copyright 2021 2023 A...

Page 268: ...over 3 Tightening torque 1 2 Nm xx1800003607 Concluding procedure Note Action Calibration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 268 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All right...

Page 269: ...CRB 1100 via myABB Business Portal www abb com myABB 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 Product manual CRB 1100 269 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights...

Page 270: ...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 the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to cr...

Page 271: ...y air pressure supply to the robot before entering the safeguarded space 3 Disconnecting the SMB connectors 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 48 2 Continue...

Page 272: ...s 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 DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety ...

Page 273: ...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 48 2 Continues on next page Product manual CRB 1100 273 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3 3 Replacing the SMB unit Continued ...

Page 274: ...e to ESD on page 48 1 Screw M3x5 12 9 Lafre 2C2B FC6 9 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 48 1 Continues on next page 274 Product manual CRB 1100 3HAC078007 001 Revision J Cop...

Page 275: ...the unit read the safety information in section The unit is sensitive to ESD on page 48 1 Tightening torque 0 3 Nm Reconnect the connectors SMB P7 SMB J1 SMB J2 Tip See the number markings on the connectors for help to find the corresponding connector 2 xx1800002468 Continues on next page Product manual CRB 1100 275 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 3...

Page 276: ...se 4 Tightening torque 1 2 Nm xx1800002467 Concluding procedure Note Action Calibration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 276 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights ...

Page 277: ...abb com myABB Note Article number Spare part 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet 3HAC069048 001 Base 3HAC083589 001 Motor with flange axis 1 3HAC061934 001 Timing belt axis 1 3HAC083588 001 Motor with flange axis 2 3HAC061935 001 Timing belt axis 2 Replace if damaged 3HAC061947 001 Mechanical stop axis 1 Continues on next page Product manual CRB 1100 277 3HAC078007 ...

Page 278: ... toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for CRB 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 ...

Page 279: ...d 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 664 If no previous reference values ...

Page 280: ...release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002488 Remove the swing support cover 3 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 4 Continues on next page 280 Product...

Page 281: ...emale head of the connector from the connector plate 6 xx1800002492 Remove the swing cover 7 xx1800002495 Disconnect the connector MP2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 8 Continues on next page Product manual CRB 1100 281 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacin...

Page 282: ...eet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 11 xx1800003603 CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step xx1800002496 Remove the timing belt from its groove on the motor 12 Continues on next page 282 Product manual CRB 1100 3HAC078007 001...

Page 283: ...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 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 Product manual CRB ...

Page 284: ...re and 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 284 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repa...

Page 285: ...necting Tip The connector clip has to be pressed 1 and pushed forward 2 to separate the J2 C2 for Ethernet cabling xx1800002943 3 Putting the robot on its side 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 CRB 1100 285 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserve...

Page 286: ...ROSTATIC 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 48 2 xx1800002467 Remove 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 c...

Page 287: ...onnecting 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 next page Product manual CRB 1100 287 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 288: ...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 288 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 289: ...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 CRB 1100 289 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repa...

Page 290: ...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 290 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 291: ...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 CRB 1100 291 ...

Page 292: ...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 292 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 293: ...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 CRB 1100 293 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 294: ...screws and washers 4 Cooling pad location Carefully 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 5 xx1800003602 Continues on next page 294 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB A...

Page 295: ...s means the axes can fall down Make sure axes are well supported before loosening timing belts 2 xx1800003067 Remove the timing belt from its groove on the gearbox 3 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 CRB 1100 295 3HAC078007 001 Revision J C...

Page 296: ...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 296 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 297: ...1 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 Product manual CRB 1100 297 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base ...

Page 298: ...tton 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 298 Product manual CRB 1100 3HAC078007 001 Revision J Copy...

Page 299: ...ation orient the motor according to the figure below in regard to the encircled motor con nector 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 xx1800003072 Continues on next page Product manual CRB 1100 299 3HAC078007 001 Revision J Copyright 2021 2023 ABB All...

Page 300: ...ull the dynamometer 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 300 Product manual CRB 1100 3HAC078007 0...

Page 301: ...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 Product manual CRB 1100 301 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the ...

Page 302: ...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 302 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5...

Page 303: ...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 Product manual CRB 1100 303 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights r...

Page 304: ...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 304 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 305: ...ing liquid after refitting Refitting the pulley cover Note Action Screw M3x8 12 9 Lafre 2C2B FC6 9 3 pcs Refit the puller cover 1 Tightening torque 1 2 Nm xx1800003043 Reconnecting the SMB connectors 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 48 1 Continues on next page Pr...

Page 306: ...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 Lafre 2C2B FC6 9 6 pcs Refit the SMB cover to the base 4 Tightening torque 1 2 Nm xx1800002467 Continues on next page 306 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacin...

Page 307: ...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 CRB 1100 307 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 308: ...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 308 Product manual CRB 1100 ...

Page 309: ...tening 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 Product manual CRB 1100 309 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserve...

Page 310: ...fre 2C2B FC6 9 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 310 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 311: ...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 help t...

Page 312: ...ck 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 Check the cooling pad Replace if damaged as shown in the following step 2 xx1800003603 Continues on next page 312 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 313: ...motor con nector Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 xx1800003027 Screw M4x16 12 9 Lafre 2C2B FC6 9 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 CRB 1100 313 3HAC078007 001 Revision J Copyright 2021 2023 ABB All ...

Page 314: ...e screw to the hole 7 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 8 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page 314 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repai...

Page 315: ...ion 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 Product manual CRB 1100 315 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5...

Page 316: ...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 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Continues on next page 316 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021...

Page 317: ...pport cover 3 Tightening torque 1 2 Nm xx1800003607 Concluding procedure Note Action Calibration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 Product manual CRB 1100 317 3HAC078007 001 Revision J Copyright 2021 2023 ABB Al...

Page 318: ... myABB Business Portal www abb com myABB Note Article number Spare part 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet 3HAC069050 001 Swing 3HAC069039 001 Swing support 3HAC069048 001 Base 3HAC069062 001 Gear unit with pulley axis 1 3HAC083589 001 Motor with flange axis 1 Continues on next page 318 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All r...

Page 319: ...and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 710 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for CRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axi...

Page 320: ... 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 proced ure is completed for calibration of the ro bot Creating new values requires possibility ...

Page 321: ...ke sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002488 Remove the swing support cover 3 Continues on next page Product manual CRB 1100 321 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserv...

Page 322: ...nect the connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 6 xx1800002492 Remove the swing cover 7 Continues on next page 322 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved...

Page 323: ...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 11 xx1800003603 CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step Continues on next ...

Page 324: ... 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 324 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 202...

Page 325: ...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 Product manual CRB 1100 325 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 ...

Page 326: ...rs 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 326 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB Al...

Page 327: ...tion by removing the foundation attachment screws and put the robot on its side 4 Disconnecting the SMB connectors 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 48 2 C...

Page 328: ... 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 329: ...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 Product manual CRB 1100 329 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 330: ...ydraulic 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 330 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repai...

Page 331: ...able 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 CRB 1100 331 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 332: ...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 332 Product manual CRB 1100 ...

Page 333: ...e 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 CRB 1100 333 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 334: ...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 334 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 335: ...crews and washers 4 Cooling pad location Carefully 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 5 xx1800003602 Continues on next page Product manual CRB 1100 335 3HAC078007 001 Revision J Copyright 2021 2023 ABB Al...

Page 336: ... means the axes can fall down Make sure axes are well supported before loosening timing belts 2 xx1800003067 Remove the timing belt from its groove on the gearbox 3 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 336 Product manual CRB 1100 3HAC078007 001 Revision J Co...

Page 337: ...m 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 CRB 1100 337 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 338: ... are well supported before remov ing gearboxes 2 xx1800003073 Remove the screws 3 xx1800003074 Pull out the gearbox 4 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 338 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved ...

Page 339: ...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 Product manual CRB 1100 339 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Re...

Page 340: ...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 Lafre 2C2B FC6 9 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 Tighten...

Page 341: ...2 9 Lafre 2C2B FC6 9 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 Product manual CRB 1100 341 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 342: ...cing the swing when putting xx1800003619 2 Refitting the base to the swing Note Action Screw M4x16 12 9 Lafre 2C2B FC6 9 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 342 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Rep...

Page 343: ...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 Check the cooling pad Replace if damaged 2 xx1800003602 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 Product manual CRB 1100 343 3HAC078007 001 Revisio...

Page 344: ...tly in the groove of the pulley 4 xx1800003072 Screw M4x16 12 9 Lafre 2C2B FC6 9 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 dynamometer hooking to the motor 1 Continues on next page 344 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 202...

Page 345: ... 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 pulley...

Page 346: ...e 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 346 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 ...

Page 347: ... 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 Product manual CRB 1100 347 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights re...

Page 348: ...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 348 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 349: ...ing liquid after refitting Refitting the pulley cover Note Action Screw M3x8 12 9 Lafre 2C2B FC6 9 3 pcs Refit the puller cover 1 Tightening torque 1 2 Nm xx1800003043 Reconnecting the SMB connectors 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 48 1 Continues on next page Pr...

Page 350: ...ly the cables can be damaged 3 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 350 Produ...

Page 351: ...fre 2C2B FC6 9 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 CRB 1100 351 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 352: ...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 352 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 353: ...f 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 CRB 1100 353 3...

Page 354: ... robot to the foundation Note Action CAUTION The CRB 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 4 pcs 24 x 13 x 2 5 Tightening Torque 50 Nm 5 Nm Continues on next page 354 Product manual CRB 1100 3H...

Page 355: ...ect 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 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 1 Tightening torque 0 8 Nm xx1800002499 Continues on next page Product manual CRB 1100 355 3HAC078007 001...

Page 356: ...move 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 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 xx1800003027 Continues on next page 356 Product manual CRB 1...

Page 357: ...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 CRB 1100 357 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 358: ...9 Tightening torque 3 5 Nm Secure the motor with the screws 9 xx1800002493 Used belt 163 174 Hz Use a sonic tension meter to measure the timing 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 358 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB Al...

Page 359: ...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 Product manual CRB 1100 359 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 360: ...ed incorrectly the cables can be damaged 3 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 360 Product manual CRB 1100 3HAC078007 ...

Page 361: ...bration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 Product manual CRB 1100 361 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 362: ...e the latest spare parts of the CRB 1100 via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC069056 001 Lower arm CRB 1100 4 0 58 3HAC069055 001 Lower arm CRB 1100 4 0 475 3HAC069058 001 Lower arm support 3HAC083588 001 Motor with flange axis 2 Continues on next page 362 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repai...

Page 363: ...3HAC063985 001 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 710 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for CRB 1100 to be fitted to the tool flange during calibration of axis 6 3H...

Page 364: ...er 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 reference calib...

Page 365: ...ng 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 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002488 Remove the swing support cover 3 Continues on next page Product manual CRB 11...

Page 366: ...ct the connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 6 xx1800002492 Remove the swing cover 7 Continues on next page 366 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5...

Page 367: ...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 11 xx1800003603 CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step Continues on next pa...

Page 368: ... 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 368 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reser...

Page 369: ...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 Product manual CRB 1100 369 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing th...

Page 370: ...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 370 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5...

Page 371: ... 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 Product manual CRB 1100 ...

Page 372: ... pressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800003007 Remove the lower arm cover 3 Continues on next page 372 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 373: ...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 6 xx1800003604 Continues on next page Product manual CRB 1100 373 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 374: ...rt is hard to loosen from the lower arm use a plastic hammer to knock on the swing support lightly 2 Route the upper cable package out of the swing support 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 374 Product manual CRB 1100 3HAC078007 001 Revision J Copy...

Page 375: ...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 CAUTION Removing gearboxes will release axes This means the axes can fall down Make sure axes are well supported before remov ing gearboxes 2 Continues on next page Product manual C...

Page 376: ...e that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003086 Pull out the upper cable harness upwards from the lower arm support 2 Continues on next page 376 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 377: ...r arm from the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1900002190 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 Pro...

Page 378: ...y 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 torque 1 9 Nm 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 supp...

Page 379: ...rm support 3 Refitting the axis 2 gearbox Note Action xx1800003083 Refit the axis 2 gearbox 1 Screw M3x30 12 9 Lafre 2C2B FC6 9 12 pcs Secure with screws 2 Tightening torque 1 9 Nm xx1800003082 Continues on next page Product manual CRB 1100 379 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 380: ... 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 Screw M5x16 12 9 Lafre 2C2B FC6 9 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 2 Tightening torque 6 Nm xx1800003079 Continues ...

Page 381: ...e 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 Cooling pad for axis 3 and 4 mo tors 3HAC071021 001 Check the cooling pad Replace if damaged 2 xx1800003604 Continues on next page Product manual CRB 1100 381 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserv...

Page 382: ...2C2B FC6 9 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 382 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the l...

Page 383: ... 7 23 94 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 7 Initial referenced force for new belt 31 34 2 N xx1900000028 Continues on next page Product manual CRB 1100 383 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 384: ...s and 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 384 Product manual CRB 1100 3HAC078007 001 Revision J Copy...

Page 385: ...d 2 Screw M2 5x6 12 9 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Screw M3x12 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 4 Tightening torque 0 4 Nm xx1800003004 Continues on next page Product manual CRB 1100 385 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 386: ...tern 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 help to find the corresponding connector 2 Continues on next page 386 Product manual CRB 1100 3HAC0780...

Page 387: ... 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 Check the cooling pad Replace if damaged as shown in the following step 2 xx1800003603 Continues on next page Product manual CRB 1100 387 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continue...

Page 388: ...tor con nector Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 xx1800003027 Screw M4x16 12 9 Lafre 2C2B FC6 9 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 388 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All ri...

Page 389: ...screw to the hole 7 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 8 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page Product manual CRB 1100 389 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair ...

Page 390: ...n 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 390 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 5...

Page 391: ...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 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 4 Tightening torque 0 8 Nm xx1800002489 Continues on next page Product manual CRB 1100 391 3HAC078007 001 Revision J Copyright 2021 2...

Page 392: ... cover Swing support cover 3 Tightening torque 1 2 Nm xx1800003610 Concluding procedure Note Action Calibration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 392 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2...

Page 393: ... via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC077335 001 Process hub with lamp unit CP CS and air hose with Ethernet 3HAC069053 001 Housing 3HAC073518 001 Gear unit with pulley axis 3 3HAC073218 001 Labyrinth sealing ring 3HAC061936 001 Timing belt axis 3 3HAC083586 001 Motor with flange axis 4 Continues on next page Product manual CRB 1100 393 3HAC078007 001 Revi...

Page 394: ... for the robot The tool box also includes a unique calibration pin for CRB 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 Sonic tension meter Used for measuring the timing belt tension Dynamometer Included in the special toolkit 3H...

Page 395: ...e 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 664 If no previous reference values exist and no new reference values can be created then reference calibration is not...

Page 396: ...d air pressure are turned off 1 xx2000002219 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 396 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 A...

Page 397: ...r assembly tool For robots with Ethernet cabling 6 xx1800002948 Disconnect the connector J5 C2 using the tool 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 CRB 1100 397 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replaci...

Page 398: ...rical 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 398 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 399: ...l supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 3 Continues on next page Product manual CRB 1100 399 3HAC078007 001 Revision J Copyright 2021...

Page 400: ... Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003031 Valid for CRB 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 400 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing...

Page 401: ...ing 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 CRB 1100 401 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 402: ...n DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003013 Remove the cable bracket 2 xx1800003014 Continues on next page 402 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 403: ...om the lower arm support 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 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 Continues on next page Product manual CRB 1100 403 3HAC078007 001 Revision J Copyright 202...

Page 404: ... 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 xx1800003605 Continues on next page 404 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 405: ...ulic pressure and air pressure are turned off 1 CAUTION Loosening timing belts will release axes This means the axes can fall down Make sure axes are well supported before loosening timing belts 2 xx1800003097 Remove the pulley cover 3 Continues on next page Product manual CRB 1100 405 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Contin...

Page 406: ...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 CRB 1100 4 0 475 Separate the wrist from the housing 3 Continues on next page 406 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights rese...

Page 407: ... 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 CRB 1100 407 3HAC078007 001 Revision J Copyright 2021 2023 ABB Al...

Page 408: ... 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 408 Product manual CRB 1100 3HAC078007 001 Revision J Copyrigh...

Page 409: ... This means the axes can fall down Make sure axes are well supported before loosening timing belts 2 xx1800003007 Remove the lower arm cover 3 xx1800003008 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page Product manual CRB 1100 409 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 410: ... 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 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 Continues on next page 410 Product manual CRB 1100 3HAC07...

Page 411: ...This means the axes can fall down Make sure axes are well supported before remov ing gearboxes 2 xx1900001425 Remove the screws on the labyrinth sealing ring 3 xx1900001417 Remove the labyrinth sealing ring lightly and evenly 4 Continues on next page Product manual CRB 1100 411 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 412: ...ousing Use these procedures to refit the housing Refitting the axis 3 gearbox Note Action xx1800003285 Refit the axis 3 gearbox 1 Continues on next page 412 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 413: ... if damaged 3 xx1900001417 Refit the labyrinth sealing ring lightly and evenly Note Make sure the labyrinth sealing ring is well fitted to the axis 3 gearbox without any deflection 4 Continues on next page Product manual CRB 1100 413 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 414: ...ers 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 torque 1 9 Nm 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 Continues on next page 414 Product ...

Page 415: ... xx1800003022 Install the timing belt to the pulleys and verify that the belt runs correctly 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 CRB 1100 415 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the hous...

Page 416: ... 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 a sonic tension meter to measure the timing 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 416 Product manual CRB 1100 3HAC078007 001 Revision...

Page 417: ...ind 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 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Continues on next page Product manual CRB 1100 417 3HAC078007 001 Revision J Copyright ...

Page 418: ...te Action xx1800003075 Valid for CRB 1100 4 0 475 Refit the the wrist to the housing 1 xx1800003100 Valid for CRB 1100 4 0 58 Refit the extender unit and wrist to the housing 2 Continues on next page 418 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 419: ...1 9 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 Lafre 2C2B FC6 9 3 pcs Refit the pulley cover 2 Tightening torque 1 2 Nm xx1800003097 Continues on next page Product manual CRB 1100 419 3HAC078007 001 Revision J Copyright ...

Page 420: ...3HAC071021 001 Check the cooling pad Replace if damaged 2 xx1800003605 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 420 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 421: ...timing belt 4 xx1800003287 xx1800003617 Install the timing belt to the motor pulley 5 Screw M3x12 12 9 Lafre 2C2B FC6 9 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 CRB 1100 421 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1...

Page 422: ...the housing 1 xx1900000037 Fit an M3x25 eye bolt o the screw hole 2 xx1900000038 Use a handheld dynamometer hooking to the eye bolt 3 Continues on next page 422 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 423: ...8 7 31 5 N xx1900000039 Tightening torque 1 4 Nm Secure the motor with the screws 5 xx1800003094 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 CRB 1100 423 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 424: ... locking screw hole on the gearbox 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 1 xx1800003017 CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary Continues on next page 424 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights rese...

Page 425: ...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 xx1800003018 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page Product manual CRB 1100 425 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the hou...

Page 426: ...iquid residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for CRB 1100 4 0 58 xx1800003001 Plug screw 3HAC064146 001 Valid for CRB 1100 4 0 58 3 Tightening torque 2 Nm Refit the plug screw and washer on the extender unit xx1800003000 Continues on next page 426 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023...

Page 427: ... FC6 9 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 Product manual CRB 1100 427 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 428: ...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 428 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued...

Page 429: ... MP5 and MP6 accessible from wrist side 2 xx1800003023 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 3 xx1800002996 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 Product manual CRB 1100 429 3HAC078007 001 Revision J Copyright 2021 2023 ABB ...

Page 430: ...itial referenced force for new belt 12 8 14 xx1900000026 Tightening torque 1 4 Nm Secure the motor with the screws 7 xx1800002995 Used belt 81 3 86 9 Hz Use a sonic tension meter to measure the timing 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 430 Product manual CRB 110...

Page 431: ... 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 Product manual CRB 1100 431 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Rep...

Page 432: ...cabling and connectors into the wrist 3 Refitting the process hub Note Action xx1800002946 Reconnect the lamp unit connector J5 UL and place the connector behind the air hose connect ors 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 shaped c...

Page 433: ...highly important If the cables are routed and secured incorrectly the cables can be damaged 5 Screw M3x8 12 9 Lafre 2C2B FC6 9 4 pcs Refit the cover 6 Tightening torque 1 2 Nm xx2000002219 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 Prod...

Page 434: ...Note Action Calibration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 434 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 435: ... 1100 4 0 58 has an extender unit connecting the housing and wrist which is located as shown in the figure xx1800002476 Continues on next page Product manual CRB 1100 435 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist ...

Page 436: ...ed for CRB 1100 4 0 58 3HAC069037 001 Extender unit 3HAC075794 001 Wrist 3HAC073519 001 Gear unit with pulley axis 4 3HAC083586 001 Motor with flange axis 4 3HAC061937 001 Timing belt axis 4 3HAC083585 001 Motor with flange axis 5 3HAC061938 001 Timing belt axis 5 3HAC083584 001 Motor with flange axis 6 3HAC061939 001 Timing belt axis 6 3HAC069054 001 Housing cover Continues on next page 436 Produ...

Page 437: ...ol 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 Sonic tension meter Used for measuring the timing belt tension Dynamometer Included in the special toolkit 3HAC071022 001 Used to refit the axis 4 motor axis 4 motor fitting tool Included in the special toolkit ...

Page 438: ... 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 664 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be ...

Page 439: ...essure are turned off 1 xx2000002219 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 Product manual CRB 1100 439 3HAC078007 001 Revision J Copyright 2021 2023 ABB All r...

Page 440: ...ly tool For robots with Ethernet cabling 6 xx1800002948 Disconnect the connector J5 C2 using the tool 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 440 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the e...

Page 441: ...wer 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 Product manual CRB 1100 441 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 442: ...es for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 3 Continues on next page 442 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 AB...

Page 443: ...that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 Continues on next page Product manual CRB 1100 443 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wris...

Page 444: ... Remove the screws and washers 4 Carefully lift out the motor 5 xx1800003295 Remove the timing belt from its groove on the motor 6 Continues on next page 444 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 445: ...axis 4 gearbox from the wrist and then loosen the locking screw 2 xx1800003000 Valid for CRB 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 Product manual CRB 1100 445 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repa...

Page 446: ...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 446 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist C...

Page 447: ...re 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 Product manual CRB 1100 447 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 448: ...ressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800003094 Loosen the screws and move the motor slightly to slacken the timing belt 3 Continues on next page 448 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the e...

Page 449: ...t to scratch the casting or damage the pad 5 xx1800003605 xx1800003096 Remove the timing belt from its groove on the motor 6 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 CRB 1100 449 3HAC078007 001 Revision J Copyright 2021 2023 ABB All ...

Page 450: ... 3 xx1800003098 Remove the timing belt from its groove on the gearbox 4 Separating 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 450 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 451: ... 4 0 475 Separate the wrist from the housing 3 xx1800003298 Valid for CRB 1100 4 0 58 Separate the extender unit and wrist from 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 Continues on next page Product manual CRB 1100 451 3HAC078007 001 Revision J Copyright 2021 2023 ABB All righ...

Page 452: ...he gearbox 4 Separating the extender unit and wrist Notice that this procedure is valid for CRB 1100 4 0 58 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 CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wri...

Page 453: ...valid for CRB 1100 4 0 58 Note Action Parallel pin 3HAC050369 032 Align the parallel pin on the extender unit with the pin hole on the wrist Note Some robots may not have the parallel pin In those cases order one and press fit it to the ex tender unit 1 xx2100001504 xx2100001505 Continues on next page Product manual CRB 1100 453 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved...

Page 454: ...fit the extender unit to the wrist 2 Tightening torque 2 Nm xx1800003311 Continues on next page 454 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 455: ...rbox and extender unit or wrist are aligned with each other 1 Valid for CRB 1100 4 0 475 xx1800003313 Valid for CRB 1100 4 0 58 xx1800003312 Continues on next page Product manual CRB 1100 455 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 456: ...x1800003075 Valid for CRB 1100 4 0 475 Refit the the wrist to the housing 1 xx1800003100 Valid for CRB 1100 4 0 58 Refit the extender unit and wrist to the housing 2 Continues on next page 456 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 457: ...x1900002191 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 Lafre 2C2B FC6 9 3 pcs Refit the pulley cover 2 Tightening torque 1 2 Nm xx1800003097 Continues on next page Product manual CRB 1100 457 3HAC078007 001 Revision J Copyright 2021 202...

Page 458: ...21 001 Check the cooling pad Replace if damaged 2 xx1800003605 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 458 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 459: ...elt 4 xx1800003287 xx1800003617 Install the timing belt to the motor pulley 5 Screw M3x12 12 9 Lafre 2C2B FC6 9 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 CRB 1100 459 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replaci...

Page 460: ...ing 1 xx1900000037 Fit an M3x25 eye bolt o the screw hole 2 xx1900000038 Use a handheld dynamometer hooking to the eye bolt 3 Continues on next page 460 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 461: ... N xx1900000039 Tightening torque 1 4 Nm Secure the motor with the screws 5 xx1800003094 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 CRB 1100 461 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 462: ... screw hole on the gearbox 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 1 xx1800003017 CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary Continues on next page 462 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 R...

Page 463: ...earbox 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 xx1800003018 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page Product manual CRB 1100 463 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender un...

Page 464: ...sidues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for CRB 1100 4 0 58 xx1800003001 Plug screw 3HAC064146 001 Valid for CRB 1100 4 0 58 3 Tightening torque 2 Nm Refit the plug screw and washer on the extender unit xx1800003000 Continues on next page 464 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All...

Page 465: ... 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 Product manual CRB 1100 465 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued...

Page 466: ...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 466 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist C...

Page 467: ...P6 accessible from wrist side 2 xx1800003296 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 3 xx1800003291 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 CRB 1100 467 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights...

Page 468: ...ferenced force for new belt 19 4 21 2 N xx1900000027 Tightening torque 1 4 Nm Secure the motor with the screws 7 xx1800003290 Used belt 151 162 Hz Use a sonic tension meter to measure the timing 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 468 Product manual CRB 1100 3HA...

Page 469: ...n nector 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 xx1800003023 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 3 xx1800002996 Continues on next page Product manual CRB 1100 469 3HAC078007 001 Revisio...

Page 470: ...orce for used belt 8 96 9 8 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 6 Initial referenced force for new belt 12 8 14 xx1900000026 Tightening torque 1 4 Nm Secure the motor with the screws 7 xx1800002995 Continues on next page 470 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All ...

Page 471: ...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 Product manua...

Page 472: ...and connectors into the wrist 3 Refitting the process hub Note Action xx1800002946 Reconnect the lamp unit connector J5 UL and place the connector behind the air hose connect ors 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 shaped connector...

Page 473: ...mportant If the cables are routed and secured incorrectly the cables can be damaged 5 Screw M3x8 12 9 Lafre 2C2B FC6 9 4 pcs Refit the cover 6 Tightening torque 1 2 Nm xx2000002219 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 Product manu...

Page 474: ...bration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 474 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 475: ...B Business Portal www abb com myABB Note Article number Spare part 3HAC083589 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 Product manual CRB 1100 475 3HAC078007 001 Revision J...

Page 476: ...r measuring the timing belt tension Dynamometer 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 work of the robot see the table Note Action Note Calibr...

Page 477: ... 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 478: ...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 478 Product manual CRB 1100 3HAC078007 001 Revision J Copyri...

Page 479: ...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 Product manual CRB 1100 479 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continu...

Page 480: ...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 480 Product manual CRB 1100 3HAC078007 001 Revision J Co...

Page 481: ... 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 Product manual CRB 1100 481 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 1 Replacing...

Page 482: ... means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800003064 Loosen the screws and move the motor slightly to slacken the timing belt 3 xx1800003065 Remove the screws and washers 4 Continues on next page 482 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 483: ... belt from its groove on the motor 6 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 Check the cooling pad Replace if damaged 2 xx1800003602 Continues on next page Product manual CRB 1100 483 ...

Page 484: ...03616 xx1800003615 Install the timing belt to the motor pulley 4 Screw M4x16 12 9 Lafre 2C2B FC6 9 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 484 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 485: ...re 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 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 1 Tightening torque 0 6 Nm xx1800003042 Continues on next page Product manual CRB 1100 485 3HAC078007 001...

Page 486: ...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 486 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 487: ... 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 on n...

Page 488: ...t 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 4 pcs 24 x 13 x 2 5 Tightening Torque 50 Nm 5 Nm Concluding procedure Note Action Calibration is detailed in section Calibration on page 653 Recalibrate the robot 1...

Page 489: ... met when performing the first test run See Test run after installation maintenance or repair on page 161 2 Product manual CRB 1100 489 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 490: ...mber Spare part 3HAC083588 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 490 Product ...

Page 491: ...uires 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 ...

Page 492: ...o 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 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 Continues on next page 492 Produ...

Page 493: ...are attached to the connector plate The connector plate cannot be removed completely until the connectors are re move from the plate 4 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 5 Continues on next page Product manual CRB 1100 493 3HAC078007 001 Revision J Copyright 2021 2023 AB...

Page 494: ...MP2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 8 xx1800002493 Loosen the screws and move the motor slightly to slacken the timing belt 9 Continues on next page 494 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 motor Continued ...

Page 495: ...03603 CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step xx1800002496 Remove the timing belt from its groove on the motor 12 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 Product manual CR...

Page 496: ...s 3HAC071020 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 Lafre 2C2B FC6 9 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 an...

Page 497: ...3027 Screw M4x16 12 9 Lafre 2C2B FC6 9 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 Product manual CRB 1100 497 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 ...

Page 498: ...dheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 6 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Tightening torque 3 5 Nm Secure the motor with the screws 7 xx1800002493 Continues on next page 498 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 m...

Page 499: ...t 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 Product manual CRB 1100 499 3HAC078007 001 Revision J Copyright 2021 2023 ABB All r...

Page 500: ...s are routed and secured incorrectly the cables can be damaged 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 500 Product manua...

Page 501: ...ion is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 Product manual CRB 1100 501 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 motor Continued ...

Page 502: ...Spare part 3HAC083587 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 502 Prod...

Page 503: ...d 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 the robot 1 Follow ...

Page 504: ...ing 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 axis 3 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 5...

Page 505: ... 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 xx1800003006 Remove the cable bracket 5 Continues on next page Product manual CRB 1100 505 3HAC078007 001 Revision J Copyright 2021 2023 ABB All...

Page 506: ...s means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800003007 Remove the lower arm cover 3 xx1800003008 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page 506 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 motor Continued ...

Page 507: ...lways use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 6 xx1800003604 xx1800003010 Remove the timing belt from its groove on the motor 7 Continues on next page Product manual CRB 1100 507 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 motor Continued ...

Page 508: ... mo tors 3HAC071021 001 Check the cooling pad Replace if damaged 2 xx1800003604 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector Orient the motor correctly and fit it into the lower arm 3 xx1800003021 Continues on next page 508 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 3 Rep...

Page 509: ...ing 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 Product manual CRB 1100 509 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 motor Continued ...

Page 510: ...ghtening torque 3 Nm Secure the motor with the screws 8 xx1800003008 Used belt 102 109 Hz Use a sonic tension meter to measure the timing 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 510 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All right...

Page 511: ...d 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 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Continues on next page Product manual CRB 1100 511 3HAC078007 001 Revision J Copyright 20...

Page 512: ...afre 2C2B FC6 9 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 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 512 Product manual ...

Page 513: ...Article number Spare part 3HAC083586 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 Product manual CRB 1100 513 3HAC...

Page 514: ...librating 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 and tools can stay fitted on the robot Fine calibration All external cable packages DressPack...

Page 515: ...ing 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 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 P...

Page 516: ...for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 Continues on next page 516 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 517: ...AUTION 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 xx1800003605 Continues on next page Product manual CRB 1100 517 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 518: ...ion 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 Check the cooling pad Replace if damaged 2 xx1800003605 Continues on next page 518 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 519: ...w in regard to the encircled motor con nector 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 xx1800003287 xx1800003617 Install the timing belt to the motor pulley 5 Continues on next page Product manual CRB 1100 519 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 m...

Page 520: ... 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 520 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 521: ...ication direction 4 New belt 28 7 31 5 N xx1900000039 Tightening torque 1 4 Nm Secure the motor with the screws 5 xx1800003094 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 CRB 1100 521 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 ...

Page 522: ... 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 522 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 4 Replaci...

Page 523: ...tailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 Product manual CRB 1100 523 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 524: ... myABB Business Portal www abb com myABB Note Article number Spare part 3HAC083585 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 710 Standard toolkit Continues on next page 524 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 ...

Page 525: ...equires 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 remove...

Page 526: ...to 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 Opening the process hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 526 Produc...

Page 527: ...re 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 Product manual CRB 1100 527 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Re...

Page 528: ... that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 Continues on next page 528 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 5 Replacing the axis 5 motor Continue...

Page 529: ...03291 Remove the screws and washers 4 Carefully lift out the motor 5 xx1800003292 Remove the timing belt from its groove on the motor 6 Continues on next page Product manual CRB 1100 529 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 5 Replacing the axis 5 motor Continued ...

Page 530: ...or con nector Orient the motor correctly and fit it into the wrist Tip Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side 2 xx1800003296 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 3 xx1800003291 Continues on next page 530 Product manual CRB 1100 3HAC078007 001 Revisi...

Page 531: ...crew to the hole 5 Initial referenced force for used belt 13 58 14 84 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 6 Initial referenced force for new belt 19 4 21 2 N xx1900000027 Continues on next page Product manual CRB 1100 531 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 ...

Page 532: ...nt loosen the motor screws and readjust 9 xx1900000008 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 532 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All ri...

Page 533: ...grease to the cover that has contacting area with the cable package 2 Screw M3x8 12 9 Lafre 2C2B FC6 9 7 pcs Refit the wrist cover 3 Tightening torque 1 2 Nm xx1800003315 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 on next...

Page 534: ...ed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 534 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 5 Replacing the axis 5 motor Continued ...

Page 535: ...B Business Portal www abb com myABB Note Article number Spare part 3HAC083584 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 710 Standard toolkit Continues on next page Product manual CRB 1100 535 3HAC078007 001 Revision J Copyright 2021 2023 ...

Page 536: ...equires 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 remove...

Page 537: ...to 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 Opening the process hub 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 ma...

Page 538: ...lic 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 538 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 6...

Page 539: ... off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 3 Continues on next page Product manual CRB 1100 539 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 6 Replacing the axis 6 motor Contin...

Page 540: ...the motor Use these procedures to refit the axis 6 motor 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 540 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 7 6 Replacing the axis 6 motor Continued ...

Page 541: ...P5 and MP6 accessible from wrist side 2 xx1800003023 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 3 xx1800002996 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 Product manual CRB 1100 541 3HAC078007 001 Revision J Copyright 2021 2023 ABB Al...

Page 542: ...ial referenced force for new belt 12 8 14 xx1900000026 Tightening torque 1 4 Nm Secure the motor with the screws 7 xx1800002995 Used belt 81 3 86 9 Hz Use a sonic tension meter to measure the timing 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 542 Product manual CRB 1100 ...

Page 543: ...t 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 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 CRB 1100...

Page 544: ...maged 1 Screw M3x8 12 9 Lafre 2C2B FC6 9 4 pcs Refit the cover 2 Tightening torque 1 2 Nm xx2000002219 Concluding procedure Note Action Calibration is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 544 Product manual CRB 1100 3...

Page 545: ... via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet 3HAC069062 001 Gear unit with pulley axis 1 3HAC069048 001 Base 3HAC083589 001 Motor with flange axis 1 3HAC061934 001 Timing belt axis 1 3HAC083588 001 Motor with flange axis 2 Continues on next page Product manual CRB 1100 545 3HAC078007 001 Revision J C...

Page 546: ...equired tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 710 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for CRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibratio...

Page 547: ... 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 664 If no previous reference values exist and no new ...

Page 548: ...se axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002488 Remove the swing support cover 3 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 4 Continues on next page 548 Product manu...

Page 549: ... head of the connector from the connector plate 6 xx1800002492 Remove the swing cover 7 xx1800002495 Disconnect the connector MP2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 8 Continues on next page Product manual CRB 1100 549 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the...

Page 550: ...ith caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 11 xx1800003603 CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step xx1800002496 Remove the timing belt from its groove on the motor 12 Continues on next page 550 Product manual CRB 1100 3HAC078007 001 Revi...

Page 551: ...nnecting 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 Product manual CRB 1100 ...

Page 552: ...d 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 552 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 ...

Page 553: ...ng Tip The connector clip has to be pressed 1 and pushed forward 2 to separate the J2 C2 for Ethernet cabling xx1800002943 3 Putting the robot on its side 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 CRB 1100 553 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 R...

Page 554: ...TIC 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 48 2 xx1800002467 Remove 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 cablin...

Page 555: ...ting 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 next page Product manual CRB 1100 555 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 556: ... 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 556 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Contin...

Page 557: ...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 CRB 1100 557 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 ...

Page 558: ... 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 558 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 559: ...urned 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 CRB 1100 559 3HAC0...

Page 560: ...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 560 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 561: ...he 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 CRB 1100 561 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 562: ...s and washers 4 Cooling pad location Carefully 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 5 xx1800003602 Continues on next page 562 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All ri...

Page 563: ...ns the axes can fall down Make sure axes are well supported before loosening timing belts 2 xx1800003067 Remove the timing belt from its groove on the gearbox 3 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 CRB 1100 563 3HAC078007 001 Revision J Copyri...

Page 564: ... 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 564 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 565: ...gearboxes will release axes This means the axes can fall down Make sure axes are well supported before remov ing gearboxes 2 xx1800003073 Remove the screws 3 xx1800003074 Pull out the gearbox 4 Continues on next page Product manual CRB 1100 565 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 566: ...e swing casting 1 Screw M3x30 12 9 Lafre 2C2B FC6 9 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 566 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replaci...

Page 567: ... the swing when putting xx1800003619 2 Refitting the base to the swing Note Action Screw M4x16 12 9 Lafre 2C2B FC6 9 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 CRB 1100 567 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replaci...

Page 568: ...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 Check the cooling pad Replace if damaged 2 xx1800003602 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 568 Product manual CRB 1100 3HAC078007 001 Revision J C...

Page 569: ...n the groove of the pulley 4 xx1800003072 Screw M4x16 12 9 Lafre 2C2B FC6 9 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 dynamometer hooking to the motor 1 Continues on next page Product manual CRB 1100 569 3HAC078007 001 Revision J Copyright 2021 202...

Page 570: ...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 571: ...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 CRB 1100 571 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repa...

Page 572: ...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 572 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserv...

Page 573: ...g 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 CRB 1100 573 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 574: ...iquid after refitting Refitting the pulley cover Note Action Screw M3x8 12 9 Lafre 2C2B FC6 9 3 pcs Refit the puller cover 1 Tightening torque 1 2 Nm xx1800003043 Reconnecting the SMB connectors 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 48 1 Continues on next page 574 Pro...

Page 575: ...he cables can be damaged 3 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 manua...

Page 576: ...C2B FC6 9 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 576 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 577: ...rake 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 CRB 1100 577 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 578: ...e 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 578 Product manual CRB 1100 3HAC0...

Page 579: ...t to the foundation Note Action CAUTION The CRB 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 4 pcs 24 x 13 x 2 5 Tightening Torque 50 Nm 5 Nm Continues on next page Product manual CRB 1100 579 3HAC078...

Page 580: ...o 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 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 1 Tightening torque 0 8 Nm xx1800002499 Continues on next page 580 Product manual CRB 1100 3HAC078007 001 Revi...

Page 581: ... 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 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 xx1800003027 Continues on next page Product manual CRB 1100 581 ...

Page 582: ...ng 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 582 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 583: ...htening torque 3 5 Nm Secure the motor with the screws 9 xx1800002493 Used belt 163 174 Hz Use a sonic tension meter to measure the timing 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 CRB 1100 583 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rig...

Page 584: ... 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 584 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 585: ...ncorrectly the cables can be damaged 3 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 CRB 1100 585 3HAC078007 001 ...

Page 586: ...on is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 586 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 587: ...er Spare part 3HAC073517 001 Gear unit with pulley axis 2 3HAC083588 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 Produc...

Page 588: ... 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 Depending on which routine is chosen action might 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 re...

Page 589: ...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 590: ...9 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 4 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 5 Continues on next page 590 Produ...

Page 591: ...P2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 8 xx1800002493 Loosen the screws and move the motor slightly to slacken the timing belt 9 Continues on next page Product manual CRB 1100 591 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 592: ...ware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step xx1800002496 Remove the timing belt from its groove on the motor 12 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 593: ...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 CRB 1100 593 3HAC078007...

Page 594: ...er 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 CAUTION Removing gearboxes will release axes This means the axes can fall down Make sure axes are well supported before remov ing gearboxes 2 Move the lower arm aside a little to access the gearbox screws 3 Continues...

Page 595: ...ke sure that all 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 CRB 1100 595 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 596: ...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 596 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 597: ...s use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 1 Tightening torque 4 2 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 CRB 1100 597 3HAC078007 001 Rev...

Page 598: ...le package to the axis 2 gearbox Note Action Screw M2 5x6 12 9 Lafre 2C2B FC6 9 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 598 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights r...

Page 599: ...crews 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 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 4 xx1800003027 Continues on next page Product manual CRB 1100 599 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights re...

Page 600: ...ng 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 600 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 601: ...htening torque 3 5 Nm Secure the motor with the screws 9 xx1800002493 Used belt 163 174 Hz Use a sonic tension meter to measure the timing 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 CRB 1100 601 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rig...

Page 602: ...r help to find the corresponding connector 13 Reconnecting the connector at the division point Note Action xx1800002491 Insert the female header of the connector to the connector plate 1 Continues on next page 602 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 603: ...the cables can be damaged 3 Screw M3x8 12 9 Lafre 2C2B FC6 9 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 CRB 1100 603 3HAC078007 001 Revision J ...

Page 604: ...on is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 604 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 605: ...100 via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC073518 001 Gear unit with pulley axis 3 3HAC073218 001 Labyrinth sealing ring 3HAC083587 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 Product manual CRB 1100 605 3HAC078007 001 Revision J Copyright 2021 202...

Page 606: ...ration pin for CRB 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 Sonic tension meter Used for measuring the timing belt tension Dynamometer Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Gre...

Page 607: ...ence 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 664 If no previous reference values exist and no new reference values can be created then reference calibration is not possible I...

Page 608: ... 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 608 Product manual CRB 1100 3HAC078007 001 Revision J Copyri...

Page 609: ...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 P...

Page 610: ...s means the axes can fall down Make sure axes are well supported before loosening timing belts 2 xx1800003007 Remove the lower arm cover 3 xx1800003008 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page 610 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continue...

Page 611: ...tted 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 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 Continues on next page Product manual CRB 1100 611 3HAC07800...

Page 612: ...s means the axes can fall down Make sure axes are well supported before remov ing gearboxes 2 xx1900001425 Remove the screws on the labyrinth sealing ring 3 xx1900001417 Remove the labyrinth sealing ring lightly and evenly 4 Continues on next page 612 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 613: ...Use these procedures to refit the axis 3 gearbox Refitting the axis 3 gearbox Note Action xx1800003285 Refit the axis 3 gearbox 1 Continues on next page Product manual CRB 1100 613 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 614: ... damaged 3 xx1900001417 Refit the labyrinth sealing ring lightly and evenly Note Make sure the labyrinth sealing ring is well fitted to the axis 3 gearbox without any deflection 4 Continues on next page 614 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 615: ... 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 torque 1 9 Nm 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 Continues on next page Product manual ...

Page 616: ...800003022 Install the timing belt to the pulleys and verify that the belt runs correctly 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 616 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 g...

Page 617: ...cs Secure the motor with the screws 4 Washer 3HAC063985 001 3 pcs Tightening torque 3 Nm xx1800003008 Used belt 102 109 Hz Use a sonic tension meter to measure the timing 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 CRB 1100 617 3HAC078007 001 Revision J C...

Page 618: ...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 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 3 Tightening torque 0 6 Nm xx1800003006 Continues on next page 618 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021...

Page 619: ...fre 2C2B FC6 9 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 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 Product manual CRB 1...

Page 620: ...Note Article number Spare part 3HAC077335 001 Process hub with lamp unit CP CS and air hose with Ethernet 3HAC073519 001 Gear unit with pulley axis 4 3HAC083586 001 Motor with flange axis 4 3HAC061937 001 Timing belt axis 4 3HAC083584 001 Motor with flange axis 6 3HAC061939 001 Timing belt axis 6 3HAC069054 001 Housing cover 3HAC069061 001 Wrist cover Continues on next page 620 Product manual CRB ...

Page 621: ... axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Included in the special toolkit 3HAC071022 001 M3x25 eye bolt Used for measuring the timing belt tension Dynamometer 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 i...

Page 622: ...ence 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 664 If no previous reference values exist and no new reference values can be created then reference calibration is not possible I...

Page 623: ...r pressure are turned off 1 xx2000002219 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 Product manual CRB 1100 623 3HAC078007 001 Revision J Copyright 2021 2023 ABB A...

Page 624: ...sembly tool For robots with Ethernet cabling 6 xx1800002948 Disconnect the connector J5 C2 using the tool 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 624 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing t...

Page 625: ...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 Product manual CRB 1100 625 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 626: ...pplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 3 Continues on next page 626 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 202...

Page 627: ...ke sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1800003031 Valid for CRB 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 Product manual CRB 1100 627 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing th...

Page 628: ... 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 628 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 629: ...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 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 2 Continues on next page Product manual CRB 1100 629 3HAC078007 001 Revision J Copyright 2021 2023 ABB All ri...

Page 630: ...UTION 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 xx1800003605 Continues on next page 630 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 631: ... pressure and air pressure are turned off 1 CAUTION Loosening timing belts will release axes This means the axes can fall down Make sure axes are well supported before loosening timing belts 2 xx1800003097 Remove the pulley cover 3 Continues on next page Product manual CRB 1100 631 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Con...

Page 632: ...ws 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 CRB 1100 4 0 475 Separate the wrist from the housing 3 Continues on next page 632 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved...

Page 633: ... hydraulic pressure and air pressure are turned off 1 CAUTION Removing gearboxes will release axes This means the axes can fall down Make sure axes are well supported before remov ing gearboxes 2 xx1800003300 Remove the screws 3 Continues on next page Product manual CRB 1100 633 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Contin...

Page 634: ...n xx1800003310 Pull out the gearbox 4 Continues on next page 634 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 635: ... sure the locking screw holes on the gearbox and extender unit or wrist are aligned with each other 1 Valid for CRB 1100 4 0 475 xx1800003313 Valid for CRB 1100 4 0 58 xx1800003312 Continues on next page Product manual CRB 1100 635 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 636: ...on xx1800003075 Valid for CRB 1100 4 0 475 Refit the the wrist to the housing 1 xx1800003100 Valid for CRB 1100 4 0 58 Refit the extender unit and wrist to the housing 2 Continues on next page 636 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 637: ... 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 Lafre 2C2B FC6 9 3 pcs Refit the pulley cover 2 Tightening torque 1 2 Nm xx1800003097 Continues on next page Product manual CRB 1100 637 3HAC078007 001 Revision J Copyright 202...

Page 638: ...071021 001 Check the cooling pad Replace if damaged 2 xx1800003605 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 638 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 639: ...ing belt 4 xx1800003287 xx1800003617 Install the timing belt to the motor pulley 5 Screw M3x12 12 9 Lafre 2C2B FC6 9 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 CRB 1100 639 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Re...

Page 640: ... housing 1 xx1900000037 Fit an M3x25 eye bolt o the screw hole 2 xx1900000038 Use a handheld dynamometer hooking to the eye bolt 3 Continues on next page 640 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 641: ...31 5 N xx1900000039 Tightening torque 1 4 Nm Secure the motor with the screws 5 xx1800003094 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 CRB 1100 641 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 642: ... the locking screw hole B on the gearbox Insert the cable package in the housing and through the axis 4 gearbox Tip Wrap the connectors with the masking tape 1 xx1800003017 CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary xx1800003601 Continues on next page 642 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repa...

Page 643: ...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 xx1800003018 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page Product manual CRB 1100 643 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4...

Page 644: ...id residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for CRB 1100 4 0 58 xx1800003001 Plug screw 3HAC064146 001 Valid for CRB 1100 4 0 58 3 Tightening torque 2 Nm Refit the plug screw and washer on the extender unit xx1800003000 Continues on next page 644 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 AB...

Page 645: ...ip 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 CRB 1100 645 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Contin...

Page 646: ...5 and MP6 accessible from wrist side 2 xx1800003023 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 3 xx1800002996 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 646 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All...

Page 647: ...al referenced force for new belt 12 8 14 xx1900000026 Tightening torque 1 4 Nm Secure the motor with the screws 7 xx1800002995 Used belt 81 3 86 9 Hz Use a sonic tension meter to measure the timing 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 CRB 1100 647 3...

Page 648: ...nd 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 648 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replac...

Page 649: ...ling and connectors into the wrist 3 Refitting the process hub Note Action xx1800002946 Reconnect the lamp unit connector J5 UL and place the connector behind the air hose connect ors 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 shaped conn...

Page 650: ...ly important If the cables are routed and secured incorrectly the cables can be damaged 5 Screw M3x8 12 9 Lafre 2C2B FC6 9 4 pcs Refit the cover 6 Tightening torque 1 2 Nm xx2000002219 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 650 Prod...

Page 651: ... is detailed in section Calibration on page 653 Recalibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run See Test run after installation maintenance or repair on page 161 2 Product manual CRB 1100 651 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 652: ...This page is intentionally left blank ...

Page 653: ...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 654: ...printed on its name plate OmniCore 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 Wrist Optimization Optimization of TCP reorientation perform ance The purpose is to improve reorientation accuracy for continuous processes like weld ing and gluing Optimization Wrist optimization wil...

Page 655: ...This is further detailed in the Application manual CalibWare Field If a service operation is done to a robot with the option Absolute Accuracy a new absolute accuracy calibration is required in order to establish full performance For most cases after replacements that do not include taking apart the robot structure standard calibration is sufficient The Absolute Accuracy option varies according to...

Page 656: ...age 659 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 657: ... marks CRB 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 CRB 1100 657 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 6 Calibration 6 2 1 S...

Page 658: ...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 658 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 6 Calibration 6 2 2 Calibration movement d...

Page 659: ...e revolution counter with the FlexPendant on page 662 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 p...

Page 660: ...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 660 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 6 Calibration 6 3 1 Updating revolution counters on OmniCore ro...

Page 661: ...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 CRB 1100 661 3HAC078007 001 Revi...

Page 662: ...ibration 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 659 7 Tap Update A dialog box is displayed warning that the u...

Page 663: ...ounting 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 se...

Page 664: ...on If calibrating the robot with reference 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 ...

Page 665: ...an 0 degrees Axis must be put in position 0 degrees 0 Special requirement X System containing SafeMove SafeMove will lose its synchronization to the controller if a new calibration is done New calibration values have to be downloaded to SafeMove and a new SafeMove calibration has to be done Make sure that the user rights admit to change the safety settings and to synchronize SafeMove How to calibr...

Page 666: ...rticle number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot The tool box also includes a unique calibra tion pin for CRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibra...

Page 667: ...0951 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 xx1600001142 Outer diameter A Product manual CRB 1100 667 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserv...

Page 668: ...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 669: ...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 Product manual CRB 1100 669 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Continued ...

Page 670: ...HAC059557 001 Protective plug for bushing Clean Room Replace if damaged or missing 3HAC061926 001 Calibration pin cover 6 mm 670 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Continued ...

Page 671: ...d with protection type Clean Room Replace if damaged or missing 3HAC059557 001 Protective plug for bushing Clean Room Replace if damaged or missing 3HAC061926 001 Calibration pin cover 6 mm Overview of the calibration procedure on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through th...

Page 672: ...ed 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 calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 If the data is opti...

Page 673: ...alibration method A brief overview of the sequence that will be run on the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 671 Follow the instructions given on the FlexPendant 5 Fitting of calibration tools The figures show the calibration tool in contact with the fixed pin on each axis The position of the complete robot shown for each axis is only an exam...

Page 674: ...indow Calibration tools in contact Axis 2 Axis 1 xx1900000114 xx1900000113 Axis 4 Axis 3 xx1900000116 xx1900000115 Continues on next page 674 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 6 Calibration 6 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 675: ...s needs to be jogged in order to release the calibration tool Jogging the axis in wrong direction will cause the calibration tool to break Directions of axis movement is shown in Calibration movement directions for all axes on page 658 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...

Page 676: ...e axis has been calibrated 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 See Calibrating with Wrist Optimiz ation method on page 679 If the standard calibration data for axes 4 5 or 6 should be updated with wrist optimization run the calibration routine Wrist Optimization 3 676 Product ...

Page 677: ...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 678: ...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 man...

Page 679: ...led for on the FlexPendant the following sequence will be run 1 Choose calibration routine Wrist Optimization 2 Modify targets for 4 point tool frame definition in Wrist Optimization routine Tip Select positions with large reorientations around the TCP For best results make sure that axis 4 and 5 have large movements en0400000906 a Jog the robot to an appropriate position A for the first approach ...

Page 680: ...bration data WARNING Robot moves automatically when pressing Calibrate 6 Wrist optimization is finished 7 Redefine verify TCP for all tools 680 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 6 Calibration 6 5 Calibrating with Wrist Optimization method Continued ...

Page 681: ...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 657 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 Product...

Page 682: ...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 683: ...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 wit...

Page 684: ...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 684 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 7 Troubleshooting 7 1 Introduction to troubleshooting Continued ...

Page 685: ...AUTION Allow hot parts to cool down 1 If the oil spill is small this step is sufficient Wipe off the oil or grease see Cleaning the CRB 1100 on page 168 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 pu...

Page 686: ... can be caused 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 mainte...

Page 687: ...nding 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 compl...

Page 688: ...orque or external forces for the joint can also be too high Recommended actions The following actions are recommended Information Action CAUTION Allow hot parts to cool down 1 Verify that the values for payload and arm load are set correctly 2 Verify that the value for ambient temperature setting in the controller is consistent with the actual operating temperature environment 3 The ways could be ...

Page 689: ...ected Consequences Communication fails to be set up between the laser scanner PLC and OmniCore The safety separation function with the laser scanner cannot be applied Possible causes The firewall for the ProfiNet network is disabled Recommended actions 1 Open RobotStudio 2 In the Controller tab page choose Communication from the Configuration group 3 Select Firewall Manager in the Type pane 4 Set ...

Page 690: ...C the PROFIsafe device information must be configured on the OmniCore controller s side first Otherwise the configured signals will not be saved in the safety module in the OmniCore controller Recommended actions 1 Open the RobotStudio 2 In the Controller tab page choose Visual SafeMove from Safety in the Configuration group 3 Check the Safe I O configurations For robots running RobotWare 7 5 or e...

Page 691: ...in the Configuration group 5 Go back to the Visual SafeMove window and write the SafeMove configurations to the controller again You will observe the signals and the communication is correctly set up Product manual CRB 1100 691 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 7 Troubleshooting 7 7 Communication failure between PLC and controller Continued ...

Page 692: ...e controller s side first Otherwise the configured signals will not be saved in the OmniCore controller Recommended actions 1 Open the RobotStudio 2 In the Controller tab page choose Visual SafeMove from Safety in the Configuration group 3 Check the Safe I O configurations The following signals can be observed xx2200000305 4 If the signals cannot be observed choose I O Engineering Tool from Config...

Page 693: ...ous situation tap the menu button after the unknown device and tap Identify in the list Verify whether the unknown device is the I O module installed on the controller If yes the LED blinks on the I O module 4 Tap Configure in the list for the unknown device 5 In the displayed I O Modernization window choose Update device in the Configuration area and select CabinetIO from the drop down list This ...

Page 694: ...actual movement speed If the communication between the OmniCore controller and laser scanner fails the controller considers this situation as that the protecting area is triggered and the speed will be limited to 0 If the communication failure remains when the operating mode is changed to Manual the Set speed value is still valid Recommended actions 1 In the FlexPendant tap I O in the main page 2 ...

Page 695: ...ed to 100 does not take effect That is the speed is still controlled by the SpeedRefresh value 0 or 20 Although the speed shown in the FlexPendant is 100 the actual speed is still controlled by the combination of the SpeedRefresh value and the speed set in motion instruction which will result in the movement stopping or moving in slow speed in the Safe area Furthermore when the STT violation is tr...

Page 696: ...tions 1 Reset the template SafeMove configuration file to factory settings and apply it to the controller 2 For scenarios to remove options de select the checkboxes of the options that require to be removed in the Collaborative Speed Control add in and apply it to the controller 3 For scenarios to reselect options de select the checkboxes of the options not required first and then select the requi...

Page 697: ... Speed Control add in is not loaded or is loaded but Global_SST configuration is removed or the ISH_UserMODE_bNot_IntemitCollab is set to 1 The system is in Auto mode or Manual Full Speed mode The robot was stopped during running a program and then manually moved to another position which is within the range of the robot return path The user stands in Protecting area and restarts the program using...

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Page 699: ... 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 robot and contro...

Page 700: ... materials in the product and their respective use throughout the product Dispose components properly according to local regulations to prevent health or environmental hazards Example application Material Base base adapter swing swing support lower arm lower arm support swing covers motors gearboxes SMB unit etc Aluminium Serial measurement board Batteries Lithium Cables motors Copper Serial measu...

Page 701: ...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 702: ...h 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 A used robot does not have the same performance as on delivery Springs brakes bearings and other parts might be worn or broken 702 Produc...

Page 703: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual CRB 1100 703 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 9 Reference information 9 1 Introduction ...

Page 704: ...nvironments IEC 61000 6 2 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments IEC 61000 6 4 Safety of machinery Safety related parts of control systems Part 1 General principles for design normative reference from ISO 10218 1 ISO 13849 1 2006 Robots and robotic devices Collaborative robots ISO TS 15066 This Technical Specification specifies sa...

Page 705: ...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 Product manual CRB 1100 705 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 9 Reference information 9 3 Unit conversion ...

Page 706: ...handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Generally screws are lubricated with Gleitmo 603 mixed with Geomet 500 or Geomet 702 in proportion 1 3 Geomet thickness varies according to screw dimensions refer to the following Geomet thickness Lubricant Dimension 3 5 μm Gleitmo 603 Geomet 500 M6 M20 any length except M20x60 3 5 μm Gleitmo 603 Geomet 72...

Page 707: ...ening torque for oil lubricated screws with slotted or cross recess head screws The following table specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque for oil lubricated screws with allen head screws...

Page 708: ...h Molycote 1000 Gleitmo 603 or equivalent with allen head screws Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 lubricated i Tightening torque Nm Class 10 9 lubricated i Dimension 8 M5 14 M6 35 28 M8 70 55 M10 120 96 M12 300 235 M16 550 460 M20 950 790 M24 i Lubricated with Molycote 1000 Gleitmo 603 ...

Page 709: ...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 Product manual CRB 1100 709 3HAC078007 001 Revision J Copyright 2021 2023 ABB A...

Page 710: ...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 711: ...VDC power supply Calibration tool box Axis Calibration 3HAC074119 001 Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for CRB 1100 to be fitted to the tool flange during calibration of axis 6 Sonic tension meter Used for measuring the timing belt tension Dynamometer Used for measu...

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Page 713: ...but delivered as a separate document for registered users on myABB Business Portal www abb com myABB Tip All documents can be found via myABB Business Portal www abb com myABB Product manual CRB 1100 713 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved 10 Spare parts 10 1 Spare part lists and illustrations ...

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Page 715: ...libWare 654 carbon dioxide extinguisher 28 cleaning 168 Cold environments 93 connecting the robot and controller cabling 88 copper disposal 700 D damaged bearings 686 dimensions robot 66 direction of axes 658 Dual PROFIsafe based laser scanner laser scanner 80 81 129 137 Dual SafetyIO based laser scanner laser scanner 82 146 E environmental information 700 equipment robot 66 ESD damage elimination...

Page 716: ...65 mechanical stop axis 1 87 mechanical stop location 87 motor axis 6 replacing 535 motor axis 5 replacing 524 motor axis 4 replacing 513 motor axis 3 replacing 502 motor axis 2 replacing 490 motor axis 1 replacing 475 mounting equipment 66 MoveAbsJ instruction 682 N national regulations 28 negative directions axes 658 neodymium disposal 700 network security 16 noise 686 O oil 31 disposal 700 oil ...

Page 717: ...robot to foundation attachment screws 56 shipping 699 signals safety 19 SMB unit replacing 269 speed adjusting 93 Speed control safety configurations 157 158 strategies 151 standards 704 ANSI 704 CAN 704 start of robot in cold environments 93 steel disposal 700 storage conditions 41 suspended mounting 60 swing replacing 318 symbols safety 19 Synchronization FlexPendant application 104 synchronizat...

Page 718: ...rist replacing 435 Wrist Optimization overview of method 679 X xx replacing 51 Z zero position checking 682 718 Product manual CRB 1100 3HAC078007 001 Revision J Copyright 2021 2023 ABB All rights reserved Index ...

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Page 720: ...7 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong New District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics Discrete Automation 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC078007 001 Rev J en Copyright 2021 2023 ABB All rights reserved Specifications subject to change without notice ...

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