ABB CRB 1100 User manual

ROBOTICS
Product manual
CRB 1100

Trace back information:
Workspace 23B version a17
Checked in 2023-06-29
Skribenta version 5.5.019

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.

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 2021-2023 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation ....................................................................................................................
15How to read the product manual ......................................................................................................
16Network security ...............................................................................................................................
171 Safety
171.1 Safety information .............................................................................................
171.1.1 Limitation of liability .................................................................................
181.1.2 Requirements on personnel ......................................................................
191.2 Safety signals and symbols .................................................................................
191.2.1 Safety signals in the manual ......................................................................
211.2.2 Safety symbols on manipulator labels .........................................................
271.3 Robot stopping functions ....................................................................................
281.4 Safety during installation and commissioning .........................................................
301.5 Safety during operation ......................................................................................
311.6 Safety during maintenance and repair ...................................................................
311.6.1 Safety during maintenance and repair .........................................................
331.6.2 Emergency release of the robot axes ..........................................................
341.6.3 Brake testing ..........................................................................................
351.7 Safety during troubleshooting ..............................................................................
361.8 Safety during decommissioning ...........................................................................
372 Manipulator description
372.1 About CRB 1100 ...............................................................................................
382.2 Technical data ..................................................................................................
422.3 Safety data .......................................................................................................
432.4 Dimensions ......................................................................................................
452.5 Working range .................................................................................................
482.6 The unit is sensitive to ESD .................................................................................
493 Installation and commissioning
493.1 Introduction to installation and commissioning .......................................................
503.2 Unpacking .......................................................................................................
503.2.1 Pre-installation procedure .........................................................................
513.2.2 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 Orienting and securing the robot ...............................................................
583.3.3 Manually releasing the brakes ...................................................................
603.3.4 Setting the system parameters for an inverted or a tilted robot .........................
653.3.5 Loads fitted to the robot, stopping time and braking distances .........................
663.3.6 Fitting equipment on the robot (robot dimensions) .........................................
713.3.7 Installation of lead-through device ..............................................................
783.3.8 Installation of laser scanner ......................................................................
863.4 Restricting the working range ..............................................................................
863.4.1 Adjusting the working range ......................................................................
873.4.2 Mechanically restricting the working range ...................................................
883.5 Electrical connection ..........................................................................................
883.5.1 Robot cabling and connection points ..........................................................
913.5.2 Customer connections .............................................................................
933.6 Start of robot in cold environments ......................................................................
943.7 Configuring the software .....................................................................................
953.7.1 Information about RobotWare and CRB 1100 ...............................................
963.7.2 Information about Collaborative Speed Control add-in ....................................
Product manual - CRB 1100 5
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Table of contents

973.7.3 Lead-through ..........................................................................................
1043.7.4 SafeMove ..............................................................................................
1043.7.4.1 The SafeMove configurator app on FlexPendant ...............................
1143.7.4.2 Configuration of SafeMove using Visual SafeMove in RobotStudio .......
1193.7.5 Speed control .........................................................................................
119
3.7.5.1 Configuration of one PROFINET-base laser scanner (RobotWare 7.5 or
earlier) .......................................................................................
125
3.7.5.2 Configuration of one PROFIsafe-based laser scanner (RobotWare 7.6 or
later and PLC acting as Master) ......................................................
129
3.7.5.3 Configuration of two PROFIsafe-based laser scanners (RobotWare 7.6 or
later and PLC acting as Master) ......................................................
133
3.7.5.4 Configuration of one PROFIsafe-based laser scanner (RobotWare 7.10 or
later and OmniCore acting as Master) ..............................................
137
3.7.5.5 Configuration of two PROFIsafe-based laser scanners (RobotWare 7.10
or later and OmniCore acting as Master) ..........................................
141
3.7.5.6 Configuration of one SafetyIO-base laser scanner (RobotWare 7.6 or
later) .........................................................................................
146
3.7.5.7 Configuration of two SafetyIO-base laser scanners (RobotWare 7.6 or
later) .........................................................................................
1513.7.5.8 Speed control strategies ...............................................................
1543.7.6 Robot status indication .............................................................................
1563.7.7 Use cases of safety configurations .............................................................
1613.8 Test run after installation, maintenance, or repair ....................................................
1634 Maintenance
1634.1 Introduction ......................................................................................................
1644.2 Maintenance schedule and expected component life ...............................................
1644.2.1 Specification of maintenance intervals ........................................................
1654.2.2 Maintenance schedule .............................................................................
1674.2.3 Expected component life .........................................................................
1684.3 Cleaning activities .............................................................................................
1684.3.1 Cleaning the CRB 1100 ............................................................................
1694.4 Inspection activities ...........................................................................................
1694.4.1 Inspecting the information labels ................................................................
1714.4.2 Inspecting the robot cabling .....................................................................
1724.4.3 Inspecting timing belts ............................................................................
1764.5 Lubricating activities ..........................................................................................
1764.5.1 Lubricating the cable package ...................................................................
1784.6 Replacing/changing activities ..............................................................................
1784.6.1 Replacing the battery pack ........................................................................
1855 Repair
1855.1 Introduction ......................................................................................................
1865.2 General procedures ...........................................................................................
1865.2.1 Mounting instructions for sealings ..............................................................
1895.2.2 Cut the paint or surface on the robot before replacing parts ............................
1905.3 Cable harness ..................................................................................................
1915.3.1 Replacing the upper cable package ...........................................................
2355.3.2 Replacing the lower cable package ............................................................
2695.3.3 Replacing the SMB unit ...........................................................................
2775.4 Swing and base ................................................................................................
2775.4.1 Replacing the base .................................................................................
3185.4.2 Replacing the swing ................................................................................
3625.5 Lower arm .......................................................................................................
3625.5.1 Replacing the lower arm ...........................................................................
3935.6 Housing, extender unit and wrist ..........................................................................
3935.6.1 Replacing the housing ..............................................................................
4355.6.2 Replacing the extender unit and wrist .........................................................
6 Product manual - CRB 1100
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Table of contents

4755.7 Motors ............................................................................................................
4755.7.1 Replacing the axis-1 motor .......................................................................
4905.7.2 Replacing the axis-2 motor ........................................................................
5025.7.3 Replacing the axis-3 motor ........................................................................
5135.7.4 Replacing the axis-4 motor ........................................................................
5245.7.5 Replacing the axis-5 motor ........................................................................
5355.7.6 Replacing the axis-6 motor ........................................................................
5455.8 Gearboxes .......................................................................................................
5455.8.1 Replacing the axis-1 gearbox ....................................................................
5875.8.2 Replacing the axis-2 gearbox ....................................................................
6055.8.3 Replacing the axis-3 gearbox ....................................................................
6205.8.4 Replacing the axis-4 gearbox ....................................................................
6536 Calibration
6536.1 Introduction to calibration ...................................................................................
6536.1.1 Introduction and calibration terminology ......................................................
6546.1.2 Calibration methods .................................................................................
6566.1.3 When to calibrate ...................................................................................
6576.2 Synchronization marks and axis movement directions .............................................
6576.2.1 Synchronization marks and synchronization position for axes .........................
6586.2.2 Calibration movement directions for all axes ................................................
6596.3 Updating revolution counters ...............................................................................
6596.3.1 Updating revolution counters on OmniCore robots ........................................
6636.4 Calibrating with Axis Calibration method ...............................................................
6636.4.1 Description of Axis Calibration ..................................................................
6666.4.2 Calibration tools for Axis Calibration ...........................................................
6686.4.3 Installation locations for the calibration tools ...............................................
6716.4.4 Axis Calibration - Running the calibration procedure ......................................
6776.4.5 Reference calibration ...............................................................................
6796.5 Calibrating with Wrist Optimization method ...........................................................
6816.6 Verifying the calibration ......................................................................................
6826.7 Checking the synchronization position ..................................................................
6837 Troubleshooting
6837.1 Introduction to troubleshooting ............................................................................
6857.2 Oil and grease stains on motors and gearboxes ......................................................
6867.3 Mechanical noise or dissonance ..........................................................................
6877.4 Manipulator collapses on power down ...................................................................
6887.5 Motor temperature too high .................................................................................
6897.6 Communication failure between PROFIsafe-based laser scanner, PLC, and controller ....
6907.7 Communication failure between PLC and controller .................................................
6927.8 Communication failure between scalable I/O device and controller .............................
6937.9 Errors related to stopped background task T_SWIFTI_LED .......................................
6947.10 Unable to change speed value in FlexPendant ........................................................
6957.11 Movement in Safe area not in full speed or at zero speed .........................................
6967.12 Unable to remove or reselect installed options in Collaborative Speed Control add-in ....
6977.13 Unexpected robot movement when starting the program in Protecting Area .................
6998 Decommissioning
6998.1 Introduction to decommissioning .........................................................................
7008.2 Environmental information ..................................................................................
7028.3 Scrapping of robot .............................................................................................
7039 Reference information
7039.1 Introduction ......................................................................................................
7049.2 Applicable standards .........................................................................................
7059.3 Unit conversion .................................................................................................
7069.4 Screw joints ....................................................................................................
Product manual - CRB 1100 7
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Table of contents

7099.5 Weight specifications .........................................................................................
7109.6 Standard toolkit ................................................................................................
7119.7 Special tools ....................................................................................................
71310 Spare parts
71310.1 Spare part lists and illustrations ...........................................................................
715Index
8 Product manual - CRB 1100
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Table of contents

Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the CRB 1100
• maintenance of the CRB 1100
• mechanical and electrical repair of the CRB 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
Note
It is the responsibility of the integrator to conduct a risk assessment of the final
application.
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/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
Product manual scope
The manual covers all variants and designs of the CRB 1100. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
Continues on next page
Product manual - CRB 1100 9
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Overview of this manual

References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC078009-001Product manual, spare parts - CRB 1100
3HAC082108-001Product specification - CRB 1100
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore con-
troller i
3HAC060860-001Product manual - OmniCore C30
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
3HAC066558-001Application manual - PROFINET Controller/Device
3HAC066559-001Application manual - Functional safety and SafeMove
3HAC032104-001Operating manual - RobotStudio
3HAC076518-003Circuit diagram - CRB 1100
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
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-
tachment screws on page 56.
• Added maintenance activities of running the Brake Check and
Cyclic Brake Check routines. See Maintenance schedule on
page 165.
• Removed maintenance activity of inspecting oil seepage and up-
dated troubleshooting description about oil and grease stains on
motors and gearboxes.
•Added a caution about cleaning the lamp unit cover. See Cleaning
methods on page 168.
• Updated the tightening torque for fitting the lamp unit cover from
0.15 Nm to 0.1 Nm.
• Added a note to remind users that mechanical stop locations
cannot be adjusted. See Adjusting the working range on page 86.
B
Continues on next page
10 Product manual - CRB 1100
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
Published in release 21C. The following updates are done in this revision:
•Added a note to the procedure of enabling the lead-through device.
•Added spare part parallel pin on extender unit and updated related
refitting procedure of extender unit.
• Corrected the description of connection point on cabinet.
• Updated the naming of timing belt tension adjustment tools, from
acoustic tensiometer and tensiometer to sonic tension meter and
dynamometer, respectively.
C
Published in release 22A. The following updates are done in this revision:
• Added information about length of thread engagement for attach-
ment screws.
• Added cautions in procedures of removing timing belts, motors
and gearboxes.
• Updated dimension figures to include dimension for bottom con-
nector interface option.
• Added troubleshooting for high motor temperature, see Motor
temperature too high on page 688.
• Updated information about Gleitmo treated screws, see Screw
joints on page 706.
• Updated information of lead-through device and laser scanner
connection and configuration due to new introduction of Collabor-
ative Speed Control add-in and new laser scanner options. See
Installation of lead-through device on page 71,Installation of laser
scanner on page 78 and Configuring the software on page 94.
•Removed caution about not to use cleaning detergents containing
ethanol, organic 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 procedure.
• Added a note about the requirement for connecting lamp unit
cabling.
E
Published in release 22C. The following updates are done in this revision
• Updated robot power cable information, see Robot cables on
page 88.
• Updated spare part numbers for axes 1-6 motors.
• Added expected life of gearboxes.
• Updated cable connection figures for safetyIO-based scanner(s).
•Added the lamp unit cabling when the controller is configured with
safety I/O device DSQC1042.
• Added a caution about carefully using of the lead-through device
on the robot.
• Updated information label figure.
• Updated the connection figures and configuration procedure of
the safetyIO-based laser scanners.
• Removed the troubleshooting for issue of RED flashing status on
Scalable I/O device and failure to move the robot.
F
Published in release 22D. The following updates are done in this revision:
•Added information about Wrist Optimization in calibration chapter.
• Added notes about installation and configuration of additional
scalable I/O device.
G
Continues on next page
Product manual - CRB 1100 11
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Overview of this manual
Continued

DescriptionRevision
Published in release 23A. The following updates are done in this revision:
• Added the direct connection between the laser scanner and Om-
niCore controller.
H
Published 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

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.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
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.
• 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 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.
Continues on next page
Product manual - CRB 1100 13
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Product documentation

• Examples of how to use the application.
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.
14 Product manual - CRB 1100
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
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 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 product
model than the one that is described in the current manual.
Product manual - CRB 1100 15
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
How to read the product manual

Network security
Network security
This product is designed to be connected to and to communicate information and
data via a network interface. It is your sole responsibility to provide, and
continuously ensure, a secure connection between the product and to your network
or any other network (as the case may be).
You shall establish and maintain any appropriate measures (such as, but not limited
to, the installation 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
breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.
16 Product manual - CRB 1100
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
Network security

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 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 original spare parts and equipment which have been tested and
approved for their intended use. 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.
Product manual - CRB 1100 17
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
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 instructions.
18 Product manual - CRB 1100
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
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.
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
Continues on next page
Product manual - CRB 1100 19
3HAC078007-001 Revision: J
© Copyright 2021-2023 ABB. All rights reserved.
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
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