ABB IRB 2400/10 Owner's manual

Product specification
Articulated robot
IRB 2400/10
IRB 2400/16
IRB 2400/L
M2004

Product specification
Articulated robot
3HAC9112-1
Rev. N
IRB 2400/10
IRB 2400/16
IRB 2400/L
M2004

The information in this manual issubject to change without notice and shouldnotbe construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in
this manual.
Exceptas may beexpresslystatedanywhere in this manual,nothing herein shall be construed
as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fit-
ness 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 per-
mission, and contents thereof must not be imparted to a third party nor be used for any unau-
thorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2004 ABB All right reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of Contents
3HAC 9112-1 Rev.N 3
Overview 5
1 Description 7
1.1 Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1.2 Different robot versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.2 Safety/Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.3.2 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.3.3 Mounting the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.4 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
1.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
1.4.2 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.4.3 Maximum load and moment of inertia for full axis 5 movement . . . . . . . . . . . . . . . . . . . . . .27
1.4.4 Wrist torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
1.5 Mounting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1.5.1 Robot tool flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1.6 Calibration and references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.6.1 Fine calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.6.2 Absolute Accuracy calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
1.7 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1.8 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
1.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
1.8.2 Performance according to ISO 9283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
1.8.3 Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
1.8.4 Stopping distance/time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
1.8.5 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
2 Specification of Variants and Options 45
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
2.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
2.1.2 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
2.1.3 Positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
2.1.4 Track Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
2.2 Floor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2.2.1 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2.2.2 Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
2.3 Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.3.1 DressPack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.3.2 Process equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
2.3.3 AW Safety options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2.3.4 Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
3 Accessories 57

Table of Contents
4 Rev.N 3HAC 9112-1

Overview
3HAC 9112-1 Rev.N 5
Overview
About this Product specification
It describes the performance of the manipulator or a complete family of manipulators
in terms of:
• The structure and dimensional prints
• The fulfilment of standards, safety and operating requirements
• The load diagrams, mounting of extra equipment, the motion and the robot reach
• The integrated auxiliary equipments as that is: Customer Connections
• The specification of variant and options available
Users It is intended for:
• Product managers and Product personnel
• Sales and Marketing personnel
• Order and Customer Service personnel
Contents Please see Table of Contents on page 3.
Revisions
Revision Description
Revision 6 - The IRB 2400/L 5-kg version cancelled
- New values for Performance Acc. to ISO 9283 added
- M2000 cancelled.
Revision G - Option 287-5 Wash removed
Revision H - Chapter Calibration and references added
- Footnote added for “Pose accuracy”
Revision J - Arc welding added in Specification of Variants and Options
Revision K - Changes in chapter Standards
- Directions of forces
Revision L - An extended load diagram for IRB 2400/16 is added
- Warranty information for Load diagrams
Revision M - Maximum load and moment of inertia for full axis 5 movement
- Wrist torque
Revision N - Changes for Calibration data
- Work range
- Explanation of ISO values (new figure and table)
- Stopping distance
- Changes in chapter Specification of Variants and Options, Track
Motion and Process equipment
- User documentation on DVD

Overview
6 Rev.N 3HAC 9112-1
Complementary Product specifications
Product
specification Description
Controller IRC5 with FlexPendant, 3HAC021785-001
Controller Software
IRC5 RobotWare 5.11, 3HAC022349-001
Robot User Documen-
tation IRC5 and M2004, 3HAC024534-001

1 Description
1.1.1 Introduction
3HAC 9112-1 Rev.N 7
1 Description
1.1 Structure
1.1.1 Introduction
General IRB 2400 is a 6-axis industrial robot, designed specifically for manufacturing
industries that use flexible robot-based automation. The robot has an open structure
that is specially adapted for flexible use, and can communicate extensively with
external systems.
Foundry robots TheFoundry robots aresuitable for operating in harsh environments and have special
surface treatment and paint for excellent corrosion protection. The connectors are
designed for severe environments, and bearings, gears and other sensitive parts are
highly protected. The IRB 2400F/10 and IRB 2400F/16 have the FoundryPlus
protection which means that the hole manipulator is IP67 classified and steam
washable.
Clean Room robots The Clean Room robots are classified for clean room class 100 according to US
Federal Standard 209 or class 5 according to ISO 14644-1.
The performed clean room test has classify the air cleanliness exclusively in terms of
concentration of airborne particles generated by the robot. Other aspects of the clean
room test or other clean room requirements are not considered.
Operating system The robot is equipped with the IRC5 controller and robot control software,
RobotWare RW. RobotWare RW supports every aspect of the robot system, such as
motion control, development and execution of application programs communication
etc. See Product specification - Controller IRC5 with FlexPendant.
Safety standards require a conroller to be connected to the robot.
For additional functionality, the robot can be equipped with optional software for
application support - for example gluing and arc welding, communication features -
network communication - and advanced functions such as multitasking, sensor
control etc. For a complete description on optional software, see Product
specification - Controller software IRC5/RobotWare Options.

1 Description
1.1.1 Introduction
8 Rev.N 3HAC 9112-1
Manipulator axes
Figure 1 The IRB 2400 manipulator has 6 axes.

1 Description
1.1.2 Different robot versions
3HAC 9112-1 Rev.N 9
1.1.2 Different robot versions
General The IRB 2400 is available in three versions and all versions can be mounted inverted.
IRB 2400/10 can also be wall mounted.
Definition of version designation
IRB 2400 / Version.
Manipulator weight
Other technical data
Robot type Handling capacity (kg) Reach (m)
IRB 2400/10 10 kg 1.55 m
IRB 2400/16 16 kg (20 kg with some limita-
tions, see chapter 1.4) 1.55 m
IRB 2400/L 7 kg 1.80 m
Prefix Description
Version LLong arm
Weight
Manipulator 380 kg
Data Description Values
Airborne noise level The sound pressure level out-
side the working space < 70 dB (A) Leq (acc. to Machinery directive 89/392 EEC)

1 Description
1.1.2 Different robot versions
10 Rev.N 3HAC 9112-1
Power consumption Path E1-E2-E3-E4 in the ISO Cube, maximum load.
Figure 2 Path E1-E2-E3-E4 in the ISO Cube, maximum load.
Speed [mm/s] Power consumption [kW]
Max. 0.61 - 0.67
1000 0.46 - 0.50
500 0.40 - 0.44
100 0.37 - 0.39

1 Description
1.1.2 Different robot versions
3HAC 9112-1 Rev.N 11
Dimensions for IRB 2400/L
Figure 3 View of the manipulator from the side, rear and above (dimensions in mm).

1 Description
1.1.2 Different robot versions
12 Rev.N 3HAC 9112-1
Dimensions for IRB 2400/10 and IRB 2400/16
Figure 4 View of the manipulator from the side, rear and above (dimensions in mm).

1 Description
1.2.1 Standards
3HAC 9112-1 Rev.N 13
1.2 Safety/Standards
1.2.1 Standards
The robot conforms to the following standards:
EN-Standards Description
EN ISO 12100-1 Safety of machinery, terminology
EN ISO 12100-2 Safety of machinery, technical specifications
EN 954-1 Safety of machinery, safety related parts of control systems
EN 60204 Electrical equipment of industrial machines
EN ISO 60204-1:2006 Safety of machinery - Electrical equipment of machines
EN ISO 10218-1:2006a
a. There is a deviation from paragraph 6.2 in that only worst case stop distances and
stop times are documented.
Robots for industrial environments - Safety requirements
EN 61000-6-4 (option) EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity
IEC-Standards Description
IEC 60529 Degrees of protection provided by enclosures
ISO-Standards Description
ISO 9409-1 Manipulating industrial robots, mechanical interface
ISO 9787 Manipulating industrial robots, coordinate systems and motions
Standards Description
ANSI/RIA R15.06/1999
(option) Safety Requirements for Industrial Robots and Robot Systems
ANSI/UL 1740-1998
(option) Safety Standard for Robots and Robotic Equipment
CAN/CSA Z 434-03
(option) Industrial Robots and Robot Systems - General Safety Require- ments

1 Description
1.2.1 Standards
14 Rev.N 3HAC 9112-1
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
Safety function Description
The Service
Information System
(SIS)
The service information system gathers information about the
robot’s usage and determines how hard the robot is used. The
usage is characterized by the speed, the rotation angles and the
load of every axis.
With this data collection, the service interval of every individual
robot of this generation can be predicted, optimized and service
activities planned ahead. The collection data is available via the
FlexPendant or the network link to the robot.
The Process Robot Generation is designed with absolute safety in
mind. It is dedicated to actively or passively avoid collisions and
offers the highest level of safety to the operators and the machines
aswell as thesurrounding and attached equipment. These features
are presented in the active and passive safety system.
The time the robot is in operation (brakes released) is indicated on
the FlexPendant. Data can also be monitored over network, using
e.g. WebWare.
The Active Safety
System Description
General The active safety system includes those software features that
maintain the accuracy of the robot’s path and those that actively
avoidcollisionswhichcan occur if the robotleavesthe programmed
path accidentally or if an obstacle is put into the robot’s path.
The Active Brake
System (ABS) All robots are delivered with an active brake system that supports
the robots to maintain the programmed path in General Stop (GS),
Auto Stop (AS) and Superior Stop (SS).
The ABS is active during all stop modes, braking the robot to a stop
with the power of the servo drive system along the programmed
path. After a specific time the mechanical brakes are activated
ensuring a safe stop.
The stopping process is in accordance with a class 1 stop. The
maximumapplicable torqueonthemost loaded axis determinesthe
stopping distance.
In case of a failure of the drive system or a power interruption, a
class 0 stop turns out. Emergency Stop (ES) is a class 0 stop. All
stops (GS, AS, SS and ES) are reconfigurable.
While programming the robot in manual mode, the enabling device
has a class 0 stop.

1 Description
1.2.1 Standards
3HAC 9112-1 Rev.N 15
The Self Tuning
Performance (STP) The Process Robot Generation is designed to run at different load
configurations, many of which occur within the same program and
cycle.
The robot’s installed electrical power can thus be exploited to lift
heavy loads, create a high axis force or accelerate quickly without
changing the configuration of the robot.
Consequently the robot can run in a “power mode” or a “speed
mode” which can be measured in the respective cycle time of one
and the same program but with different tool loads. This feature is
based on QuickMoveTM.
The respective change in cycle time can be measured by running
the robot in NoMotionExecution with different loads or with
simulation tools like RobotStudio.
The Electronically
Stabilised Path (ESP) The load and inertia of the tool have a significant effect on the path
performance of a robot. The Process Robot Generation is equipped
with a system to electronically stabilize the robot’s path in order to
achieve the best path performance.
This has an influence while accelerating and braking and
consequently stabilizes the path during all motion operations with a
compromise of the best cycle time. This feature is secured through
TrueMoveTM.
Over-speed protection The speed of the robot is monitored by two independent computers.
Restricting the working
space The movement of each axis can be restricted using software limits.
As options axes 1-2 can also be restricted by means of mechanical
stops and axis 3 by an electrically switch.
Collision detection
(option) In case of an unexpected mechanical disturbance, such as a collision, electrode sticking, etc., the robot will detect the collision,
stop on the path and slightly back off from its stop position,
releasing tension in the tool.
The Passive Safety
System Description
General The Process Robot Generation has a dedicated passive safety
system that by hardware construction and dedicated solutions is
designed to avoid collisions with surrounding equipment. It
integrates the robot system into the surrounding equipment safely.
Compact robot arm
design The shape of the lower and upper arm system is compact, avoiding
interference into the working envelope of the robot.
Thelowerarmis shapedinward,givingmore spaceunderthe upper
arm to re-orientate large parts and leaving more working space
while reaching over equipment in front of the robot.
The rear side of the upper arm is compact, with no components
projecting over the edge of the robot base even when the robot is
moved into the home position.
Moveable mechanical
limitation of main axes
(option)
Axes1-2canbeequippedwith moveable mechanical stops,limiting
the working range of every axis individually. The mechanical stops
are designed to withstand a collision even under full load.
The Active Safety
System Description

1 Description
1.2.1 Standards
16 Rev.N 3HAC 9112-1
Electronic Position
Switches (EPS) on up
to 7 axes (option)
EPS offers axes position status signals, fulfilling applicable
regulations for personnel safety. Five outputs can each be
configured to reflect the position of a single axis or a combination of
axes. For each output, the range for each included axis can be set
arbitrarily.
The Internal Safety
Concept Description
General The internal safety concept of the Process Robot Generation is
basedona two-channel circuit that is monitored continuously.Ifany
component fails, the electrical power supplied to the motors shuts
off and the brakes engage.
Safety category 3 Malfunction of a single component, such as a sticking relay, will be
detected at the next MOTOR OFF/MOTOR ON operation. MOTOR
ON is then prevented and the faulty section is indicated. This
complies with category 3 of EN 954-1, Safety of machinery - safety
related parts of control Systems - Part 1.
Selecting the operating
mode The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the FlexPendant,
i.e. not by any external equipment.
Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s
(600 inch/min.). The speed limitation applies not only to the TCP
(Tool Center Point), but to all parts of the robot. It is also possible to
monitor the speed of equipment mounted on the robot.
Threepositionenabling
device The enabling device on the FlexPendant must be used to move the robot when in manual mode. The enabling device consists of a
switch with three positions, meaning that all robot movements stop
when either the enabling device is pushed fully in, or when it is
released completely. This makes the robot safer to operate.
Safe manual
movement The robot is moved using a joystick instead of the operator having to look at the FlexPendant to find the right key.
Emergency stop There is one emergency stop push button on the controller and
another on the FlexPendant. Additional emergency stop buttons
can be connected to the robot’s safety chain circuit.
Safeguarded space
stop The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light
curtains. This allows the robot’s safety functions to be activated
both by peripheral equipment and by the robot itself.
Delayed safeguarded
space stop A delayed stop gives a smooth stop. The robot stops the same way asatanormal program stop withno deviation fromtheprogrammed
path. After approx. 1 second the power supplied to the motors is
shut off.
Hold-to-run control “Hold-to-run” means that you must depress the start button in order
to move the robot. When the button is released the robot will stop.
The hold-to-run function makes program testing safer.
Fire safety Both the manipulator and control system comply with UL’s
(Underwriters Laboratories Inc.) tough requirements for fire safety.
Safety lamp (option) Asan option,therobotcan beequippedwith a safetylampmounted
on the manipulator. This is activated when the motors are in the
MOTORS ON state.
The Passive Safety
System Description

1 Description
1.3.1 Introduction
3HAC 9112-1 Rev.N 17
1.3 Installation
1.3.1 Introduction
General The same version of the robot can either be mounted on the floor or inverted. An end
effector, max. weight 7, 10 or 16kg including payload, can be mountedon the robot’s
mounting flange (axis 6) depending on the robot version.
See section 1.4 Load diagrams.
Other equipment Other equipment can be mounted on the upper arm, max. weight 11 kg or 12 kg, and
on the base, max. weight 35 kg. Holes for mounting extra equipment, see
chapter 1.5 Mounting equipment and Figure 12 and Figure 13.
Working range The working range of axes 1-2 can be limited by mechanical stops and axis 3 by limit
switches. Electronic Position Switches can be used on all axes for position indicator
of manipulator.

1 Description
1.3.2 Operating requirements
18 Rev.N 3HAC 9112-1
1.3.2 Operating requirements
Protection standards
Clean room standards
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Relative humidity
Robot Version/Protection Standard Protection standard IEC529
Standard and Clean Room Manipulator IP54
IRB 2400F/L and C/L
Manipulator
Wrist
Connectors
IP55
IP67
IP67
IRB 2400F/10, F/16
Manipulator IP67, Steam washable
US Federal Standard 209 Class 100
ISO 14644-1 Class 5
Description Standard/Option Temperature
Manipulator during opera-
tion Standard + 5°C (41°F) to + 45°C (113°F)
For the controller Standard/Option See Product specification - Con-
troller IRC5 with FlexPendant
Complete robot during
transportation and storage Standard - 25°C (-13°F) to + 55°C (131°F)
For short periods (not
exceeding 24 hours) Standard up to + 70°C (158°F)
Description Relative humidity
Complete robot during transportation and
storage Max. 95% at constant temperature
Complete robot during operation Max. 95% at constant temperature