ABB Robotics IRB 1100 User manual

ROBOTICS
Product manual
IRB 1100

Trace back information:
Workspace 20B version a15
Checked in 2020-06-01
Skribenta version 5.3.033

Product manual
IRB 1100-4/0.475
IRB 1100-4/0.58
OmniCore
Document ID: 3HAC064992-001
Revision: C
© Copyright 20192020 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, 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 from ABB.
Original instructions.
© Copyright 20192020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
11Product documentation ....................................................................................................................
13How to read the product manual ......................................................................................................
151 Safety
151.1 Safety information .............................................................................................
151.1.1 Limitation of liability .................................................................................
161.1.2 Requirements on personnel ......................................................................
171.2 Safety signals and symbols .................................................................................
171.2.1 Safety signals in the manual ......................................................................
191.2.2 Safety symbols on manipulator labels .........................................................
251.3 Robot stopping functions ....................................................................................
261.4 Installation and commissioning ............................................................................
281.5 Operation ........................................................................................................
281.5.1 Unexpected movement of robot arm ...........................................................
291.6 Maintenance and repair ......................................................................................
291.6.1 Maintenance and repair ............................................................................
321.6.2 Emergency release of the robot axes ..........................................................
331.6.3 Brake testing ..........................................................................................
341.7 Troubleshooting ................................................................................................
351.8 Decommissioning ..............................................................................................
372 Technical data
372.1 Technical data ..................................................................................................
412.2 Dimensions ......................................................................................................
432.3 Working range .................................................................................................
462.4 The unit is sensitive to ESD .................................................................................
473 Installation and commissioning
473.1 Introduction to installation and commissioning .......................................................
483.2 Unpacking .......................................................................................................
483.2.1 Transportation bracket (3HAC068893-001) ...................................................
503.2.2 Pre-installation procedure .........................................................................
513.2.3 Risk of tipping/stability .............................................................................
533.3 On-site installation ............................................................................................
533.3.1 Lifting the robot ......................................................................................
533.3.1.1 Lifting the robot by one person .......................................................
553.3.1.2 Lifting and rotating a suspended mounted robot ................................
563.3.2 Manually releasing the brakes ...................................................................
583.3.3 Orienting and securing the robot ...............................................................
603.3.4 Setting the system parameters for a suspended or a tilted robot ......................
653.3.5 Loads fitted to the robot, stopping time and braking distances .........................
663.3.6 Installation of signal lamp (option) ..............................................................
673.3.7 Fitting equipment on the robot (robot dimensions) .........................................
723.4 Restricting the working range ..............................................................................
723.4.1 Axes with restricted working range .............................................................
733.4.2 Mechanically restricting the working range ...................................................
743.5 Electrical connections ........................................................................................
743.5.1 Robot cabling and connection points ..........................................................
773.5.2 Customer connections .............................................................................
793.6 Start of robot in cold environments ......................................................................
814 Maintenance
814.1 Introduction ......................................................................................................
Product manual - IRB 1100 5
3HAC064992-001 Revision: C
© Copyright 20192020 ABB. All rights reserved.
Table of contents

824.2 Maintenance schedule and expected component life ...............................................
824.2.1 Specification of maintenance intervals ........................................................
834.2.2 Maintenance schedule .............................................................................
844.2.3 Expected component life .........................................................................
854.3 Cleaning activities .............................................................................................
854.3.1 Cleaning the IRB 1100 ..............................................................................
874.4 Inspection activities ...........................................................................................
874.4.1 Inspecting the information labels ................................................................
894.4.2 Inspecting the robot for oil seepage ............................................................
904.4.3 Inspecting the robot cabling .....................................................................
914.4.4 Inspecting timing belts ............................................................................
954.5 Lubricating activities ..........................................................................................
954.5.1 Lubricating the cable package ...................................................................
974.6 Replacing/changing activities ..............................................................................
974.6.1 Replacing the battery pack ........................................................................
1035 Repair
1035.1 Introduction ......................................................................................................
1045.2 General procedures ...........................................................................................
1045.2.1 Performing a leak-down test ......................................................................
1055.2.2 Mounting instructions for sealings ..............................................................
1085.2.3 Cut the paint or surface on the robot before replacing parts ............................
1095.3 Cable harness ..................................................................................................
1105.3.1 Replacing the upper cable package ...........................................................
1525.3.2 Replacing the lower cable package ............................................................
1865.3.3 Replacing the SMB unit ...........................................................................
1945.4 Swing and base ................................................................................................
1945.4.1 Replacing the base .................................................................................
2355.4.2 Replacing the swing ................................................................................
2795.5 Lower arm .......................................................................................................
2795.5.1 Replacing the lower arm ...........................................................................
3105.6 Housing, extender unit and wrist ..........................................................................
3105.6.1 Replacing the housing ..............................................................................
3525.6.2 Replacing the extender unit and wrist .........................................................
3905.7 Motors ............................................................................................................
3905.7.1 Replacing the axis-1 motor .......................................................................
4055.7.2 Replacing the axis-2 motor ........................................................................
4175.7.3 Replacing the axis-3 motor ........................................................................
4285.7.4 Replacing the axis-4 motor ........................................................................
4395.7.5 Replacing the axis-5 motor ........................................................................
4495.7.6 Replacing the axis-6 motor ........................................................................
4595.8 Gearboxes .......................................................................................................
4595.8.1 Replacing the axis-1 gearbox ....................................................................
5015.8.2 Replacing the axis-2 gearbox ....................................................................
5185.8.3 Replacing the axis-3 gearbox ....................................................................
5335.8.4 Replacing the axis-4 gearbox ....................................................................
5596 Calibration
5596.1 Introduction to calibration ...................................................................................
5596.1.1 Introduction and calibration terminology ......................................................
5606.1.2 Calibration methods .................................................................................
5626.1.3 When to calibrate ...................................................................................
5636.2 Synchronization marks and axis movement directions .............................................
5636.2.1 Synchronization marks and synchronization position for axes .........................
5646.2.2 Calibration movement directions for all axes ................................................
5656.3 Updating revolution counters ...............................................................................
5696.4 Calibrating with Axis Calibration method ...............................................................
5696.4.1 Description of Axis Calibration ..................................................................
5726.4.2 Calibration tools for Axis Calibration ...........................................................
6 Product manual - IRB 1100
3HAC064992-001 Revision: C
© Copyright 20192020 ABB. All rights reserved.
Table of contents

5756.4.3 Installation locations for the calibration tools ...............................................
5786.4.4 Axis Calibration - Running the calibration procedure ......................................
5846.4.5 Reference calibration ...............................................................................
5866.5 Verifying the calibration ......................................................................................
5876.6 Checking the synchronization position ..................................................................
5897 Troubleshooting
5897.1 Introduction to troubleshooting ............................................................................
5917.2 Oil and grease stains on motors and gearboxes ......................................................
5927.3 Mechanical noise or dissonance ..........................................................................
5947.4 Manipulator collapses on power down ...................................................................
5958 Decommissioning
5958.1 Introduction ......................................................................................................
5968.2 Environmental information ..................................................................................
5988.3 Scrapping of robot .............................................................................................
5999 Reference information
5999.1 Introduction ......................................................................................................
6009.2 Applicable standards .........................................................................................
6029.3 Unit conversion .................................................................................................
6039.4 Screw joints ....................................................................................................
6069.5 Weight specifications .........................................................................................
6079.6 Standard toolkit ................................................................................................
6089.7 Special tools ....................................................................................................
60910 Spare parts
60910.1 Spare part lists and illustrations ...........................................................................
611Index
Product manual - IRB 1100 7
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© Copyright 20192020 ABB. All rights reserved.
Table of contents

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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the IRB 1100
• maintenance of the IRB 1100
• mechanical and electrical repair of the IRB 1100
The robot described in this manual has the following protection types:
•Standard
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
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/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
Product manual scope
The manual covers all variants and designs of the IRB 1100. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC064994-001Product manual, spare parts - IRB 1100
3HAC064993-001Product specification - IRB 1100
3HAC066314-009Circuit diagram - IRB 1100
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore con-
troller i
Continues on next page
Product manual - IRB 1100 9
3HAC064992-001 Revision: C
© Copyright 20192020 ABB. All rights reserved.
Overview of this manual

Document IDDocument name
3HAC060860-001Product manual - OmniCore C30
3HAC073706-001Product manual - OmniCore C90XT
3HAC065036-001Operating manual - OmniCore
3HAC066554-001Application manual - Controller software OmniCore
3HAC030421-001Application manual - CalibWare Field
3HAC066553-001Technical reference manual - Event logs for RobotWare 7
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC065041-001Technical reference manual - System parameters
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition.A
Published in release 20A. The following updates are done in this revision:
• Added information about o-rings on axis-2, -3, and -4 gearboxes.
• Updated refitting steps of brake release button.
• Updated the figures of screws that are used to secure the swing
to lower arm, the lower arm to housing, the housing to extender
unit and the housing to wrist.
• Added information of resonance sounds in troubleshooting for
mechanical noise or dissonance.
•Clarified text about position of robot and added table with depend-
encies between axes during Axis Calibration.
•Clarified and added information in mounting instructions for rotat-
ing sealings, see Mounting instructions for sealings on page 105.
• FlexPendant terminology updated for calibration procedures.
B
Published in release 20B. The following updates are done in this revision:
• Removed spare part O-rings that are on axis-2, -3, and -4 gear-
boxes because they are not used for protection class IP40.
• Added instructions of cutting the paint or surface on the robot
before replacing parts.
•Article number of Calibration tool box, Axis Calibration is changed
from 3HAC062326-001 to 3HAC074119-001.
• Installation of signal lamp is updated.
• Supported controller OmniCore C90XT is added.
C
10 Product manual - IRB 1100
3HAC064992-001 Revision: C
© Copyright 20192020 ABB. All rights reserved.
Overview of this manual
Continued