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 ......................................................................................................
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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 ...........................................................
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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
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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
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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
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Overview of this manual
Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• 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 system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 15.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.
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How to read the product manual

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1 Safety
1.1 Safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment
ABB supplies original spare parts and equipment which have been tested and
approved. The installation and/or use of non-original spare parts and equipment
can negatively affect the safety, function, performance, and structural properties
of the robot. ABB is not liable for damages caused by the use of non-original spare
parts and equipment.
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1 Safety
1.1.1 Limitation of liability

1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Personal protective equipment
Use personal protective equipment, as stated in the product manual.
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1 Safety
1.1.2 Requirements on personnel

1.2 Safety signals and symbols
1.2.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
For more information, see standard ISO 13849.
SignificanceDesignationSymbol
Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
DANGER
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in serious
injury.
WARNING
Signal word used to indicate a potentially hazardous
situation related to electrical hazards which, if not
avoided, could result in serious injury.
ELECTRICAL
SHOCK
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in slight
injury.
CAUTION
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in severe
damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
Signal word used to indicate important facts and
conditions.
NOTE
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1 Safety
1.2.1 Safety signals in the manual

SignificanceDesignationSymbol
Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.
TIP
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1 Safety
1.2.1 Safety signals in the manual
Continued

1.2.2 Safety symbols on manipulator labels
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 19.
The information labels can contain information in text.
Symbols on safety labels
DescriptionSymbol
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!
xx0900000811
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
xx0900000839
Used in combinations with other symbols.
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1 Safety
1.2.2 Safety symbols on manipulator labels

DescriptionSymbol
See user documentation
xx0900000813
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
Before disassemble, see product manual
xx0900000816
Do not disassemble
xx0900000815
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
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1 Safety
1.2.2 Safety symbols on manipulator labels
Continued