Product specification

Articulated robot
IRB 2400 - 7/1.8 IRB 2400 - 10/1.55 IRB 2400 - 16/1.55 M2004

Product specification
Articulated robot
3HAC 9112-1
Rev.H IRB 2400 - 7/1.8 IRB 2400 - 10/1.55 IRB 2400 - 16/1.55 M2004

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, damages 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 ABBs written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized 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 Robotics SE-721 68 Vsters Sweden

Table of Contents
Overview 1 Description 5 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 1.2.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.3.2 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.3.3 Mounting the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.3.4 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.3.5 Mounting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.3.6 Robot tool flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4 Calibration and references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.4.1 Fine calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.4.2 Absolute Accuracy calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.5 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.6.2 Performance according to ISO 9283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1.6.3 Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1.6.4 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2 Specification of Variants and Options 35

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.1.2 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3 Accessories 43

3HAC 9112-1

Rev.H

Table of Contents

Rev.H

3HAC 9112-1

Overview

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 i.e: 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
Revision 6

Description
- The IRB 2400/L 5-kg version cancelled - New values for Performance Acc. to ISO 9283 added - M2000 cancelled. - Option 287-5 Wash removed - Chapter Calibration and references added - Footnote added for Pose accuracy

Revision G Revision H

Complementary Product specifications Product specification

Controller Controller Software IRC5 Robot User Documentation

Description
IRC5 with FlexPendant, 3HAC021785-001 RobotWare 5.07, 3HAC022349-001 IRC5 and M2004, 3HAC024534-001

3HAC 9112-1

Rev.H

Overview

Rev.H

3HAC 9112-1

1 Description
1.1.1 Introduction

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

The Foundry robots are suitable 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. RobotWare and BaseWare OS 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.

3HAC 9112-1

Rev.H

1 Description
1.1.1 Introduction

Manipulator axes

Axis 4 Axis 5

Axis 6 Axis 3

Axis 2

Axis 1

Figure 1 The IRB 2400 manipulator has 6 axes.

Rev.H

3HAC 9112-1

1 Description
1.1.2 Different robot versions

1.1.2 Different robot versions

General

The IRB 2400 is available in different versions depending on its handling capacity and environment protection.
Available robot versions

The following robot versions are available, floor mounting or inverted.

Environment adaption
Standard Foundry Clean room

Pay load 7 kg
IRB 2400/L IRB 2400F/L IRB 2400CR/L

Pay load 10 kg
IRB 2400/10 IRB 2400F/10 IRB 2400CR/10

Pay load 16 kg
IRB 2400/16 IRB 2400F/16 IRB 2400CR/16

Definition of version designation

IRB 2400 Application / Version - Handling capacity.

Prefix
Version Protection L F or C CR

Description
Long arm Manipulator adapted for use in harsh environments (e.g. foundry robot is required) Manipulator is clean room classified handling capacity Indicates the maximum handling capacity (kg)

Manipulator weight Weight

Manipulator 380 kg

Other technical data Data Description Values

Airborne noise level The sound pressure level out- < 70 dB (A) Leq (acc. to Machinery side the working space directive 89/392 EEC)

3HAC 9112-1

Rev.H

1 Description
1.1.2 Different robot versions

Power consumption

Path E1-E2-E3-E4 in the ISO Cube, maximum load.

Speed [mm/s]
Max. 1000 500 100

Power consumption [kW]

0.61 - 0.67 0.46 - 0.50 0.40 - 0.44 0.37 - 0.39

1 P2

E2 P30

P 40 P10 E E3 630 mm
Figure 2 Path E1-E2-E3-E4 in the ISO Cube, maximum load.

10

Rev.H

3HAC 9112-1

1 Description
1.1.2 Different robot versions

Dimensions for IRB 2400/L

1225 870 150 290 360 180 65 260

855

268 176

251 138

1730

615

446

100 305 723 R = 448

C L 600

180

R = 76 444 R = 347 A

389

123

A- A

R = 330
Figure 3 View of the manipulator from the side, rear and above (dimensions in mm).

3HAC 9112-1

Rev.H

454
11

1 Description
1.1.2 Different robot versions

Dimensions for IRB 2400/10 and IRB 2400/16

705

135

180

1065 755

306 85 133

176

268

251

138

1564

615

180

100 305 723 R = 448

446

C L 600

R = 98 444 78 R = 347 A (163) 85 A A- A

389

R = 330

Figure 4 View of the manipulator from the side, rear and above (dimensions in mm).

12

Rev.H

3HAC 9112-1

454

1 Description
1.2.1 Standards

1.2 Safety/Standards
1.2.1 Standards
The robot conforms to the following standards:

EN-Standards
EN ISO 12100-1 EN ISO 12100-2 EN 954-1 EN 60204 EN 61000-6-4 (option) EN 61000-6-2 EN 775

Description
Safety of machinery, terminology Safety of machinery, technical specifications Safety of machinery, safety related parts of control systems Electrical equipment of industrial machines EMC, Generic emission EMC, Generic immunity Manipulating industrial robots, safety

IEC-Standards
IEC 60204-1 IEC 60529

Description
Electrical equipment of industrial machines Degrees of protection provided by enclosures

ISO-Standards
ISO 10218 ISO 9409-1 ISO 9787

Description
Manipulating industrial robots, safety Manipulating industrial robots, mechanical interface Manipulating industrial robots, coordinate systems and motions

Standards
ANSI/RIA R15.06/ 1999 (option) ANSI/UL 17401998 (option)

Description
Safety Requirements for Industrial Robots and Robot Systems Safety Standard for Robots and Robotic Equipment

CAN/CSA Z 434-03 Industrial Robots and Robot Systems - General Safety Requirements (option)

The robot complies fully with the health and safety standards specified in the EECs Machinery Directives.

3HAC 9112-1

Rev.H

13

1 Description
1.2.2 Safety

1.2.2 Safety
The robot is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any 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.
Three position enabling 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.
Over-speed protection

The speed of the robot is monitored by two independent computers.

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 robots safety chain circuit.

14

Rev.H

3HAC 9112-1

1 Description
1.2.2 Safety

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 robots 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 in the same way as at a normal program stop with no deviation from the programmed path. After approx. 1 second the power supplied to the motors shuts off.
Collision detection (option)

In case of an unexpected mechanical disturbance like a collision, electrode sticking etc. appears, the robot will stop and slightly back off from its stop position.
Restricting the working space

The movement of each axis can be restricted using software limits. Axes 1-2 can also be restricted by means of mechanical stops and axis 3 by an electrically switch (option).
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 ULs (Underwriters Laboratories) tough requirements for fire safety.
Safety lamp (option)

The robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.

3HAC 9112-1

Rev.H

15

1 Description
1.3.1 Introduction

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 16 kg including payload, can be mounted on the robots mounting flange (axis 6) depending on the robot version. See section 1.3.4 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 1.3.5 Mounting equipment and Figure 9 and Figure 10.
Working range

The working range of axes 1-2 can be limited by mechanical stops and axis 3 by limit switches. Position switches can be supplied on axis 1 for position indicator of manipulator.

16

Rev.H

3HAC 9112-1

1 Description
1.3.2 Operating requirements

1.3.2 Operating requirements

Protection standards Robot Version/Protection Standard
Standard and Clean Room Manipulator IRB 2400F/L and C/L Manipulator Wrist Connectors IRB 2400F/10, F/16 Manipulator

Protection standard IEC529

IP54 IP55 IP67 IP67 IP67, Steam washable

Clean room standards

US Federal Standard 209 ISO 14644-1 Class 100 Class 5

Explosive environments

The robot must not be located or operated in an explosive environment.

Ambient temperature Description
Manipulator during operation Complete robot during transportation and storage, Complete robot during transportation and storage, for short periods (not exceeding 24 hours)

Temperature
+5C (+41F) to +45C (+113F) -25C (-13F) to +55C (+131F) up to +70C (+158F)

Relative humidity Description

Complete robot during transportation and storage Complete robot during operation

Relative humidity
Max. 95% at constant temperature Max. 95% at constant temperature

3HAC 9112-1

Rev.H

17

1 Description
1.3.3 Mounting the manipulator

1.3.3 Mounting the manipulator

Maximum load in relation to the base coordinate system. See Figure 5.
IRB 2400/L Endurance load in operation Max. load at emergency stop
Force xy Force z floor mounting Force z inverted mounting Torque xy Torque z 1700 N + 4100 1100 N - 4100 1100 N 3000 Nm 450 Nm 2100 N + 4100 1400 N - 4100 1400 N 3400 Nm 900 Nm

IRB 2400/10 and IRB 2400/16 Endurance load in operation Max. load at emergency stop
Force xy Force z floor mounting Force z inverted mounting Torque xy Torque z 2000 N + 4100 1400 N - 4100 1400 N 3400 Nm 550 Nm 2600 N + 4100 1900 N - 4100 1900 N 4000 Nm 900 Nm

18

Rev.H

3HAC 9112-1

1 Description
1.3.3 Mounting the manipulator

X B 280 B Z A 48 D = 18.5 Y D = 18.5 (2x) B-B (A)

0.5

A (B) 260 (C)

Figure 5 Hole configuration (dimensions in mm).

210

260

48 20

0.25 A- A

D = 35 -0

+0.039

H8 (2x)

Pos
A B C

Description
Z = center line axis 1 The same dimensions View from the bottom of the base

3HAC 9112-1

Rev.H

19

1 Description
1.3.4 Load diagrams

1.3.4 Load diagrams

IRB 2400/L

Z (mm) 600

1 kg 500

400

1.5 kg

2 kg 300

3 kg 200 4 kg 5 kg 6 kg 7 kg

100

L (mm) 65 100 200 300 400

Figure 6 Maximum weight permitted for load mounting on the mounting flange at different positions (center of gravity).

Description
Z L J See the above diagram and the coordinate system in the Product specification - IRC5 with FlexPendant Distance in X -Y plane from Z - axis to the center of gravity Maximum own moment of inertia on the total handling weight = d 0.012 kgm2

20

Rev.H

3HAC 9112-1

1 Description
1.3.4 Load diagrams

IRB 2400/10

Z (mm)

200 6 kg 150 8 kg 100 10 kg 12 kg 50

L (mm) 100 85 150 200

Figure 7 Maximum weight permitted for load mounting on the mounting flange at different positions (center of gravity).

Description
Z L J See the above diagram and the coordinate system in the Product specification - IRC5 with FlexPendant Distance in X -Y plane from Z - axis to the center of gravity Maximum own moment of inertia on the total handling weight = d 0.040 kgm2

3HAC 9112-1

Rev.H

21

1 Description
1.3.4 Load diagrams

IRB 2400/16

Z (mm)

200

150

10 kg 12 kg 14 kg 16 kg

100

50

L (mm) 100 85 150 200

Figure 8 Maximum weight permitted for load mounting on the mounting flange at different positions (center of gravity).

Description
Z L J See the above diagram and the coordinate system in the Product specification - IRC5 with FlexPendant Distance in X -Y plane from Z - axis to the center of gravity Maximum own moment of inertia on the total handling weight = d 0.060 kgm2

22

Rev.H

3HAC 9112-1

1 Description
1.3.5 Mounting equipment

1.3.5 Mounting equipment

The robot is supplied with tapped holes on the upper arm and on the base for mounting extra equipment.
IRB 2400/L
300

M5 (2x) Depth 9 37 37 62 70 (2x)

A
Max. 10kg
400

D-D

D
67

M8 (2x) Depth 14 Max. 1kg

135

150

30 170

D=200

400

470

A-A
M8 (3x) R=92 Depth 16

C L

120o (3x)

38o

B-B

M8 (3x) R=77 Depth 16 120o (3x)

Max. 35 kg total

C B
D=50
150

38o

B C C-C
(A)

Figure 9 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).

Pos
A

Description
The rear side of the manipulator

3HAC 9112-1

Rev.H

23

1 Description
1.3.5 Mounting equipment

IRB 2400/10 and IRB 2400/16

300

M6 (2x)

M8 (3x) Depth of thread 14

400 70 35

25

110

65
450

177

M5 (2x)

300

100 D=240 22 78 43 90 200 Max. 2kg

A-A

Max. 10kg

M8 (3x) R=92 Depth 16

38o

B-B
M8 (3x) R=77 Depth 16 120o (3x) Max. 35 kg total

C B
D=50 150

38o 120o (3x)

B C C-C
(A)

Figure 10 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).

Pos
A

Description
The rear side of the manipulator

24

Rev.H

3HAC 9112-1

1 Description
1.3.6 Robot tool flange

1.3.6 Robot tool flange

IRB 2400/L A
45
o

D=6 -0 H7 0.05 B M6 (4x)

+0.012

9 H8

D=25 -0

R=20

90o (4x)

6 A-A

Figure 11 The mechanical interface, mounting flange (dimensions in mm).

IRB 2400/10 and IRB 2400/16 A H7, depth min 8 D=6 -0 0.05 B
30
o

+0.012

M6 (6x)
5x
60 o

10 R=25 D=31,5 +0.039H8 -0

A 7 A-A
Figure 12 The mechanical interface, mounting flange (dimensions in mm).

3HAC 9112-1

Rev.H

D=63 -0.046 h8

+0

D=50 -0.039 h8 B
25

+0.027

+0

1 Description
1.4.1 Fine calibration

1.4 Calibration and references

1.4.1 Fine calibration
General

Fine calibration is made using the Calibration Pendulum, please see Operating manual - Calibration Pendulum.
Axis 4 Axis 5

Axis 6 Axis 3

Axis 2

Axis 1

Figure 13 All axes in zero position.

Calibration Calibration
Calibration of all axes Calibration of axis 1 and 2 Calibration of axis 1

Position
All axes are in zero position Axis 1 and 2 in zero position Axis 3 to 6 in any position Axis 1 in zero position Axis 2 to 6 in any position

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1 Description
1.4.2 Absolute Accuracy calibration

1.4.2 Absolute Accuracy calibration

General

Requires RobotWare option Absolute Accuracy, please see Product specification Controller software IRC5 for more details.
The calibration concept

Absolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute accuracy of better than 1 mm in the entire working range. Absolute accuracy compensates for:
Mechanical tolerances in the robot structure Deflection due to load

Absolute accuracy calibration is focusing on positioning accuracy in the cartesian coordinate system for the robot. It also includes load compensation for deflection caused by the tool and equipment. Tool data from robot program is used for this purpose. The positioning will be within specified performance regardless of load.
Calibration data

The user is supplied with robot calibration data (compensation parameter file, absacc.cfg) and a certificate that shows the performance (Birth certificate). The difference between an ideal robot and a real robot without AbsAcc can typically be 8 mm, resulting from mechanical tolerances and deflection in the robot structure.

3HAC 9112-1

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1 Description
1.4.2 Absolute Accuracy calibration

Absolute Accuracy option

Absolute Accuracy option is integrated in the controller algorithms for compensation of this difference and does not need external equipment or calculation. Absolute Accuracy is a RobotWare option and includes an individual calibration of the robot (mechanical arm). Absolute Accuracy is a TCP calibration in order to Reach (m) a good positioning in the Cartesian coordinate system.

Figure 14 The Cartesian coordinate system.

Production data

Typical production data regarding calibration are:

Positioning accuracy (mm) Robot Average
IRB 2400L IRB 2400/10 IRB 2400/16 0,40 0,30

Max
0,80 0,70

% Within 1 mm
100 100

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Rev.H

3HAC 9112-1

1 Description
1.5.1 Introduction

1.5 Maintenance and Troubleshooting

1.5.1 Introduction
General

The robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible:
Maintenance-free AC motors are used. Oil is used for the gear boxes. The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change.

The following maintenance is required:

Changing filter for the drive system cooling every year. Changing batteries every 3rd year. Changing oil in the wrist after the first year and then every 5th year.

Maintenance

The maintenance intervals depend on the use of the robot. For detailed information on maintenance procedures, see Maintenance section in the Product Manual.

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1 Description
1.6.1 Introduction

1.6 Robot Motion

1.6.1 Introduction
IRB 2400/L

The working area is the same for both floor and inverted mounting.

Type of motion
Axis 1 Rotation motion Axis 2 Arm motion Axis 3 Arm motion Axis 4 Wrist motion Axis 5 Bend motion Axis 6 Turn motion
3421

Range of movement
+180 to -180 +110 to -100 +65 to -60 +185 to -185 +115 to -115 +400 to -400 (Unlimited as optional)

Pos 1 Axis 4

Pos 0 (A)

Axis 3 1702 + + Pos 6 Axis 2 Pos 5 + + + Axis 5

52 R= 1

Axis 6 2885

Pos 2

X
Axis 1

Pos 3 Pos 4 1810

100
00

560

R= 570

4 R=

Pos 4

(B)

Figure 15 The extreme positions of the robot arm (dimensions in mm).

Pos
A B

Description
Wrist center Positions at wrist center (mm) and angle (degrees) see the following table

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Rev.H

3HAC 9112-1

1 Description
1.6.1 Introduction

Positions at wrist center (mm) and Angle (degrees) for IRB 2400/L:

Position no (see Figure 15)

0 1 2 3 4 5 6

Angle Position (mm) Position (mm) (degrees) X Z Axis 2

970 404 602 1577 400 -1611 -115 1620 2298 745 -246 -403 623 1088 0 0 0 110 110 -100 -100

Angle (degrees) Axis 3

0 -60 65 -60 24.5 -60 65

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1 Description
1.6.1 Introduction

IRB 2400/10 and IRB 2400/16

The working area is the same for both floor and inverted mounting. For wall mounted 10 kg version axis 1 rotation is limited to 30.

Type of motion
Axis 1 Rotation motiona Axis 2 Arm motion Axis 3 Arm motion Axis 4 Wrist motion Axis 5 Bend motion Axis 6 Turn motion

Range of movement
+180 to -180 +110 to -100 +65 to -60 +200 to -200 (Unlimited as optional) +120 to -120 +400 to -400 (Unlimited as optional)

a. +30 to -30 for wall mounted 10 kg version.

2900 Pos 1

Z
Axis 4

Pos 0 (A)

Axis 3 1441 + + Pos 6 Axis 2 Pos 5 + Axis 5

R= 448

+ + Axis 6 2458

Pos 2

Axis 1 100 Pos 4 1550

0 40

Pos 3 393

R= 570

R=

(B) Pos 4

Figure 16 The extreme positions of the robot arm (dimensions in mm).

Pos
A B

Description
Wrist center Positions at wrist center (mm) and angle (degrees) see the following table

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1 Description
1.6.2 Performance according to ISO 9283

Positions at wrist center (mm) and Angle (degrees) for IRB 2400/10 and IRB 2400/16:

Angle Position no Position (mm) Position (mm) (degrees) (see Figure 16) X Z Axis 2
0 1 2 3 4 5 6 855 360 541 1351 400 -1350 -53 1455 2041 693 -118 -302 624 1036 0 0 0 110 110 -100 -100

Angle (degrees) Axis 3

0 -60 65 -60 18.3 -60 65

1.6.2 Performance according to ISO 9283

General

At rated load and 1.6 m/s velocity on the inclined ISO test plane with all six robot axes in motion.

IRB Description
Pose repeatability, RP (mm) Pose accuracy, AP (mm) Linear path accuracy, AT (mm) Pose stabilization time, Pst (s) within 0.4 mm of the position
a

IRB 2400/L Values

0.07 0.04 0.78 0.14

IRB 2400/10

IRB 2400/16

0.03 0.03 0.11 0.33 0.15

0.03 0.03 0.15 0.41 0.22

Linear path repeatability, RT (mm) 0.11

a. AP according to the ISO test above, is the difference between the teached position (position manually modified in the cell) and the average position obtained during program execution.

The above values are the range of average test results from a number of robots.

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1 Description
1.6.3 Velocity

1.6.3 Velocity

Axis no.
1 2 3 4 5 6

IRB 2400/L
150/s 150/s 150/s 360/s 360/s 450/s

IRB 2400/10
150/s 90/sa 150/s 90/sa 150/s 90/sa 360/s 360/s 450/s

IRB 2400/16
150/s 150/s 150/s 360/s 360/s 450/s

a. For wall mounted 10 kg version

Supervision is required to prevent overheating in applications with intensive and frequent movements.
Resolution

Approx. 0.01o on each axis.

1.6.4 Signals
For more information of air and signals for extra equipment to upper arm, see Application Interface in chapter 2 Specification of Variants and Options.

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2 Specification of Variants and Options

2.1.1 General

2 Specification of Variants and Options

2.1 Introduction
2.1.1 General
The different variants and options for the IRB 2400 are described below. The same numbers are used here as in the Specification form. For controller options, see Product specification - Controller IRC5 with FlexPendant, and for software options, see Product specification - Controller software IRC5/RobotWare.

2.1.2 Manipulator
Variants Standard Option 287-4
IRB 2400/L IRB 2400/10 IRB 2400/16

Option
435-9 435-7 435-8

Foundry Option 287-3

IRB 2400F/L IRB 2400F/10 IRB 2400F/16

Clean Room Option 287-1

IRB 2400CR/L IRB 2400CR/10 IRB 2400CR/16

Manipulator color Option

209-1 209-2 209-4--192

Description
The robot is painted in color ABB Orange. The robot is painted in white color. The manipulator is painted with the chosen RAL-color.

Mounting position Option

224-1 224-2 224-3

Description
Floor mounted Inverted Wall mounteda

a. For 10 kg version, limited axis 1 rotation to 30 and reduced speed axis 1, 2 and 3 to 90/s.

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2 Specification of Variants and Options

2.1.2 Manipulator

Protection Option
287-4 Standard 287-3 Foundry Robot adapted for foundry or other harsh environments. Degree of protection as in chapter 1.3.2. The manipulator is finished with a special coating. 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 whole manipulator is IP67 classified and steam washable. The robot is labeled with Foundry (IRB 2400F/L) or Foundry Plus (IRB 2400F/10 and F/16). Robot with clean room class 100 according to US Federal Standard 209 and with the same protection as in option 287-4. The robot is labeled with Clean Room.

Description

287-1 Clean Room

Application interface

Air supply and signals for extra equipment to upper arm. For connection of extra equipment on the manipulator, there are cables integrated into the manipulators cabling, one FCI UT07 14 12SH44N connector and one FCI UT07 18 23SH44N connector on the rear part of the upper arm. A hose for compressed air is also integrated into the manipulator. There is an inlet (R1/4) at the base and an outlet (R1/4) on the upper arm.
Signals Power Air 23 10 1 50 V, 250 mA 250 V, 2 A Max. 8 bar, inner hose diameter 8 mm

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2 Specification of Variants and Options

2.1.2 Manipulator

Option
218-8

Description
Integrated hose and cables for connection of extra equipment on the manipulator to the rear part of the upper arm.

218-6

Hose and cables for connection of extra equipment are extended to the wrist on the outside of the upper arm. Not possible on IRB 2400/L, option 435-9.

218-3

Integrated wire feed cabling Control signals: 16 signals, 49 V, 500 mA Connector on upper arm housing: FCI 23-pin UTG 618-23PN Connector on robot base: FCI 23-pin socket UT001823SHT Power signals: 12 signals, 300 V, 4 A Connector on upper arm housing: FCI 12-pin socket UTG 614-12SN Connector on robot base: FCI 12-pin UT001412PHT Not possible on IRB 2400/10 and /16.

Connection to Option
16-2 Manipulator 16-1 Cabineta

Description
The signals are connected directly to the manipulator base to one 40pins Harting connector. The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, to the the controller. Not together with option 218-3.

if 218-6 if 16-1

a. Note! In a M2004 MultiMove application additional robots have no Control Module. The screw terminals with internal cabling are then delivered separately to be mounted in the main robot Control Module or in another encapsulation, e.g. a PLC cabinet.

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2 Specification of Variants and Options

2.1.2 Manipulator

Connection to cabinet (cable length) Option

94-1 94-2 94-3 94-4

Description
7m 15 m 22 m 30 m

Safety lamp Option

213-1

Description
A safety lamp with an orange fixed light can be mounted on the manipulator. The lamp is active in MOTORS ON mode. The safety lamp is required on a UL/UR approved robot.

Position switch

Switches indicating the position of axis 1. A design with two stationary or 1, 2 or 3 adjustable switches is available. The switches are manufactured by Telemecanique or Burnstein, and of type forced disconnect.
Note that the switches are not recommended to be used in severe environments with sand or chips.

Switches axis 1, adjustable

For more information see Figure 17:

Option
25-2 25-4 25-3

Description
One switch Two switches Three switches

(A)
Figure 17 Connections of the switches

Pos
A

Description
Controller

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2 Specification of Variants and Options

2.1.2 Manipulator

Two switches, axis 1 stationary Option

25-5

Description
Two switches, axis 1, stationary (see Figure 18) The two switches divide the working area of axis 1 into two fixed working zones, approx. 175 each. Together with external safety arrangement, this option allows access to one working zone at the same time as the robot is working in the other one.

(A)

Figure 18 Connections of the switches.

Pos
A

Description
Controller

Switches connected to Option

271-2 271-1

Description
Manipulator Connection on the manipulator base with one FCI 23-pin connector. Cabinet Connection on the cabinet wall. Position switch cables are included. The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST- 5.08.

Switches cable lengths

Only together with option 271-1:

Option
273-1 273-2 273-3 273-4

Cable lengths
7m 15 m 22 m 30 m

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2 Specification of Variants and Options

2.1.2 Manipulator

Connector kit

Detached connectors, suitable to the connectors for the application interface and position switches. The kit consists of connectors, pins and sockets.

Option
431-1 239-1 426-1

Description
For the connectors on the upper arm if application interface, option 218-8 or option 218-6. For the connectors on the foot if connection to manipulator, option 16-2. For connection to position switches and connection to manipulator, option 271-2 and option position switch(es).

Working range limit

To increase the safety of the robot, the working range of axes 1, 2 and 3 can be restricted.

Option
28-1

Description
Axis 1 Two extra stops for restricting the working range. The stops can be mounted within the area from 50 to 140. See Figure 19.

140 50

50 140
Figure 19 Mounting area of the stops.

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2 Specification of Variants and Options

2.1.2 Manipulator

Option
32-1

Description
Axis 2 Stop lugs for restricting the working range. Figure 20 illustrates the mounting positions of the stops.

20 40 50 80 70

Figure 20 Mounting positions of the stops.

Option
34-1

Description
Axis 3 Equipment for electrically restricting the working range in increments of 5

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2 Specification of Variants and Options

2.1.2 Manipulator

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3 Accessories

3 Accessories
General

There is a range of tools and equipment available, specially designed for the robot.
Basic software and software options for robot and PC

For more information, see Product specification - Controller IRC5 with FlexPendant, and Product specification - Controller software IRC5/RobotWare.
Robot Peripherals
Track Motion Motor Units

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3 Accessories

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Index

A accessories, 43 air supply, 36 C calibration, 26, 27 connector kit, 40 cooling device, 9 E emergency stop, 14 enabling device, 14 equipment mounting, 23 permitted extra load, 23 extra equipment connections, 36 F fire safety, 15 H hold-to-run control, 15 humidity, 17 I installation, 16 inverted robot, 16 L load, 16, 18 load diagrams, 20 M maintenance, 29 manipulator colors, 35 mechanical interface, 25 motion, 30 mounting extra equipment, 23 robot, 18 mounting flange, 25 N noise level, 9 O operating requirements, 17 option Absolute Accuracy, 27 options, 35 overspeed protection, 14 P payload, 16 performance, 33 position switch, 38 positioning accuracy, 28 protection

foundry, 36 standard, 36 protection standards, 17 R range of movement working space, 30 reduced speed, 14 references, 26 repeatability, 33 Robot Peripherals, 43 robot versions, 9 S safeguarded space stop, 15 delayed, 15 safety, 13 safety lamp, 15, 38 service, 29 service position indicator, 38 signal connections, 36 space requirements, 9 standards, 13 structure, 7 suspended robot, 16 T temperature, 17 troubleshooting, 29 V Variants, 35 variants, 35 W weight, 9 working space restricting, 15, 16, 40

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Index

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ABB Robotics S-721 68 VSTERS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592

3HAC9112-1, Revision H, en