robotics productspecification irb2400 · 2021. 6. 2. · 1description 1.1structure...

ROBOTICS

Product specificationIRB 2400

Trace back information:Workspace 21B version a5Checked in 2021-05-27Skribenta version 5.4.005

Product specificationIRB 2400/10IRB 2400/16

Document ID: 3HAC042195-001Revision: R

© Copyright 2004-2021 ABB. All rights reserved.Specifications subject to change without notice.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damage to personsor property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Keep for future reference.Additional copies of this manual may be obtained from ABB.

Original instructions.


Table of contents7Overview of this product specification .............................................................................................

91 Description91.1 Structure .........................................................................................................91.1.1 Introduction to structure ...........................................................................

111.1.2 Different robot versions ............................................................................131.2 Standards ........................................................................................................131.2.1 Applicable standards ...............................................................................151.3 Installation .......................................................................................................151.3.1 Introduction to installation .........................................................................161.3.2 Operating requirements ............................................................................171.3.3 Mounting the manipulator .........................................................................201.4 Calibration and references ..................................................................................201.4.1 Calibration methods .................................................................................221.4.2 Fine calibration .......................................................................................231.4.3 Absolute Accuracy calibration ...................................................................251.5 Load diagrams ..................................................................................................251.5.1 Introduction to load diagrams ....................................................................291.5.2 Maximum load and moment of inertia for full and limited axis 5 movement .........301.5.3 Wrist torque ...........................................................................................311.6 Mounting equipment ..........................................................................................311.6.1 Information about mounting equipment .......................................................341.7 Maintenance and troubleshooting .........................................................................351.8 Robot motion ....................................................................................................381.9 Signals ............................................................................................................

392 Specification of variants and options392.1 Introduction to variants and options ......................................................................402.2 Manipulator ......................................................................................................452.3 Positioners .......................................................................................................462.4 Track motion ....................................................................................................472.5 Floor cables .....................................................................................................472.5.1 Manipulator ............................................................................................482.5.2 Positioner ..............................................................................................492.6 Process ...........................................................................................................492.6.1 DressPack .............................................................................................502.6.2 Process equipment ..................................................................................512.7 User documentation ..........................................................................................

533 Accessories533.1 Introduction to accessories .................................................................................

55Index

Product specification - IRB 2400 53HAC042195-001 Revision: R

© Copyright 2004-2021 ABB. All rights reserved.

Table of contents

This page is intentionally left blank

Overview of this product specificationAbout this product specification

It describes the performance of themanipulator or a complete family of manipulatorsin terms of:

• The structure and dimensions prints• The fulfillment of standards, safety and operating requirements• The load diagrams, mounting or extra equipment, the motion and the robot

reach• The specification of variants and options available

UsageProduct specifications are used to find data and performance about the product,for example to decide which product to buy. How to handle the product is describedin the product manual.

UsersIt is intended for:

• Product managers and product personnel• Sales and marketing personnel• Order and customer service personnel

References

Document IDReference

3HAC047400-001Product specification - Controller IRC5IRC5 with main computer DSQC1000.

3HAC050945-001Product specification - Controller software IRC5IRC5 with main computer DSQC1000 and RobotWare 5.6x.

3HAC050945-001Product specification - Controller software IRC5IRC5 with main computer DSQC1000 and RobotWare 6.

3HAC022031-001Product manual - IRB 2400

3HAC052355-001Product specification - Robot user documentation, IRC5 with RobotWare6

Revisions

DescriptionRevision• Replaces 3HAC9112-1 (English), 3HAC10766-1 (French),

3HAC10393-1 (German), 3HAC10759-1 (Spanish), and 3HAC10780-1 (Italian)

-

• Machinery directive updated• IRB 2400L removed• General corrections/update

A

• General updates and minor correctionsB• General updates and minor correctionsC

Continues on next pageProduct specification - IRB 2400 73HAC042195-001 Revision: R


Overview of this product specification

DescriptionRevision• Minor corrections and updatesD• Text for ISO test adjustedE• Text for Foundry Plus updated.• Minor corrections/update

F

• Minor corrections/updateG• Minor corrections/updateH• Section Track motion with options 1001-1, 1000-5 and 1000-6 re-

moved from manual.J

• Unit changed from N to Nm for Torque in section "Maximum loadIRB 2400/10/16".

K

Published in release R17.1. The following updates are done in this revi-sion:

• Restriction of load diagram added.

L

Published in release R17.2 The following updates are done in this revision:• Updated list of applicable standards.

M

Published in release R18.1 The following updates are done in this revision:• Minor changes on load diagrams general description.

N

Published in release 19C. The following updates are done in this revision:• Note added about need to calibrate if the robot is other than floor

mounted. See Calibration methods on page 20• Updated information about Absolute Accuracy.

P

Published in release 20D. The following updates are done in this revision:• Warranty section updated.

Q

Published in release 21B. The following updates are done in this revision:• Text regarding fastener quality is updated.• Added information, see Information for replacement of manipulator

on page 12.• Removed Axis resolution.

R

8 Product specification - IRB 24003HAC042195-001 Revision: R


Overview of this product specificationContinued

1 Description1.1 Structure

1.1.1 Introduction to structure

Robot familyThe IRB 2400 is a 6-axis industrial robot, designed specifically for manufacturingindustries that use flexible robot-based automation. The robot has an open stucturethat is specially adapted for flexible use, and can communicate extensively withexternal systems.

Operating systemThe robot is equipped with the IRC5 controller and robot control software,RobotWare. RobotWare supports every aspect of the robot system, such asmotioncontrol, development and execution of application programs, communication etc.see Product specification - Controller IRC5 with FlexPendant.

SafetySafety standards valid for complete robot, manipulator and controller.

Additional functionalityFor additional functionality, the robot can be equipped with optional software forapplication support - for example gluing and welding, communication features -network communication - and advanced functions such as multi-tasking, sensorcontrol, etc. For a complete description on optional software, see Productspecification - Controller software IRC5.

Foundry PlusFoundry PlusThe Foundry Plus option is designed for harsh environments where the robot isexposed to sprays of coolants, lubricants and metal spits that are typical for diecasting applications or other similar applications. Typical applications are sprayinginsertion and part extraction of die-castingmachines, handling in sand casting andgravity casting, etc.. Special care must be taken in regard to operational andmaintenance requirements for applications in foundry are as well as in otherapplications areas. Please contact ABB Robotics Sales organization if in doubtregarding specific application feasibility for the Foundry Plus robot. The FoundryPlus robot is painted with two-component epoxy on top of a primer for corrosionprotection. To further improve the corrosion protection additional rust preventiveare applied to exposed and crucial areas, e.g. has the tool flange a specialpreventive coating. Although, continuous splashing of water or other similar rustformation fluids may case rust attach on the robots unpainted areas, joints, or otherunprotected surfaces. Under these circumstances it is recommended to add rustinhibitor to the fluid or take other measures to prevent potential rust formation onthe mentioned.The entire robot is IP67 compliant according to IEC 60529 - from



1 Description1.1.1 Introduction to structure

base to wrist (except IRB 2400L, IP67 only on wrist and connectors), which meansthat the electrical compartments are sealed against water and solid contaminants.Among other things all sensitive parts are better protected than the standard offer.Selected Foundry Plus features:- Improved sealing to prevent penetration into cavities to secure IP67- Additional protection of cabling and electronics- Special covers protecting cavities- Well-proven connectors- Rust preventives on screws, washers and unpainted/machined surfaces- Extended service and maintenance programThe Foundry Plus robot can be cleaned with appropriate washing equipment.The robot is labeled with “Foundry” (IRB 2400F/L) or “Foundry Plus” (IRB 2400F/10and F/16).

Manipulator axes

(A)

(B)

(C)

(D)(E)

(F)

-

-

-

-

-

-

++

+

+

+

+

xx1100000569

DescriptionPosDescriptionPos

Axis 2BAxis 1A

Axis 4DAxis 3C

Axis 6FAxis 5E



1 Description1.1.1 Introduction to structureContinued

1.1.2 Different robot versions

GeneralThe IRB 2400 is available in two variants and they can be mounted inverted (notilting allowed around X-axis or Y-axis).

Reach (m)Handling capacity (kg)Robot type

1.5510IRB 2400/10

1.5516 (20 kg with some limita-tions, see Load diagrams onpage 25)

IRB 2400/16

Manipulator weight

WeightRobot type

380 kgIRB 2400/10(/16)

Other technical data

NoteDescriptionData

< 70 dB (A) Leq (acc. to Ma-chinery directive 2006/42/EG)

The sound pressure leveloutside the working space

Airborne noise level

Power consumption at max load

IRB 2400/10 (/16)Type of Move-ment

0.61 - 0.67 kWISO Cube Max.velocity

xx0900001012

DescriptionPos

630 mmA



1 Description1.1.2 Different robot versions

Dimensions IRB 2400/10 and IRB 2400/16

180

1065

755 85

18

0

61

57

05

13

5

15

64

723

305

100

44

43

89

R = 448

R = 347

R = 330

85

78

(16

3)

A

A

A - A

R = 98

600

CL

44

6

45

4

176 268 138251

133

306

xx1100000546

Information for replacement of manipulatorThe R1.MP and R1.CP/CS connectors on the manipulator on protection typeStandard were changed in May 2018, from clamp locking connections to screwlocking connections. So if a newmanipulator will replace an older manipulator thennew floor cables are needed (power cable and CP/CS, same as for protection typeFoundry Plus).More details are available in Product manual - IRB 2400.



1 Description1.1.2 Different robot versionsContinued

1.2 Standards

1.2.1 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phasedout or replaced standards are removed from the list when needed.

GeneralThe product is designed in accordance with ISO 10218-1:2011, Robots for industrialenvironments - Safety requirements -Part 1 Robots, and applicable parts in thenormative references, as referred to from ISO 10218-1:2011. In case of deviationsfrom ISO 10218-1:2011, these are listed in the declaration of incorporation whichis part of the product delivery.

Normative standards as referred to from ISO 10218-1

DescriptionStandard

Manipulating industrial robots - Performance criteria and relatedtest methods

ISO 9283:1998

Robots and robotic devices - Safety requirements for industrialrobots - Part 2: Robot systems and integration

ISO 10218-2

Safety of machinery - General principles for design - Risk as-sessment and risk reduction

ISO 12100

Safety of machinery - Safety related parts of control systems- Part 1: General principles for design

ISO 13849-1:2006

Safety of machinery - Emergency stop - Principles for designISO 13850

Safety of machinery - Electrical equipment of machines - Part1: General requirements

IEC 60204-1:2005

Safety of machinery - Functional safety of safety-related elec-trical, electronic and programmable electronic control systems

IEC 62061:2005

Region specific standards and regulations

DescriptionStandard

Safety requirements for industrial robots and robot systemsANSI/RIA R15.06

Safety standard for robots and robotic equipmentANSI/UL 1740

Industrial robots and robot Systems - General safety require-ments

CAN/CSA Z 434-14

Other standards used in design

DescriptionStandard

Robots and robotic devices -- Coordinate systems and motionnomenclatures

ISO 9787:2013

Electromagnetic compatibility (EMC) – Part 6-2: Genericstandards – Immunity standard for industrial environments

IEC 61000-6-2



1 Description1.2.1 Applicable standards

DescriptionStandard

Electromagnetic compatibility (EMC) – Part 6-4: Genericstandards – Emission standard for industrial environments

IEC 61000-6-4(option 129-1)

Ergonomics of the thermal environment - Part 1ISO 13732-1:2008

Arc welding equipment - Part 1: Welding power sourcesIEC 60974-1:2012 i

Arc welding equipment - Part 10: EMC requirementsIEC 60974-10:2014 i

Classification of air cleanlinessISO 14644-1:2015 ii

Degrees of protection provided by enclosures (IP code)IEC 60529:1989 + A2:2013i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.ii Only robots with protection Clean Room.



1 Description1.2.1 Applicable standardsContinued

1.3 Installation

1.3.1 Introduction to installation

GeneralThe same version of the robot can either be mounted on the floor or inverted (notilting allowed around X-axis or Y-axis). An end effector, max. weight 10 or 16 kgincluding payload, can be mounted on the robot’s mounting flange (axis 6)depending on the robot version.See Load diagrams on page 25.

Extra loadsOther 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, seeMounting equipment on page 31.

Working range limitationsThe working range of axes 1-2 can be limited by mechanical stops and axis 3 bylimit switches. Electronic Position Switches can be used on all axes for positionindicator of manipulator.



1 Description1.3.1 Introduction to installation

1.3.2 Operating requirements

Protection standards

Protection Standard IEC60529Robot version

IP54Standard manipulator

IP67, Steam washableIRB 2400/10, /16 Foundry Plus

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

Ambient temperature

TemperatureStandard/OptionDescription

+ 5°C i (41°F) to + 45°C (113°F)StandardManipulator during operation

See Product specification - ControllerIRC5 with FlexPendant

Standard/OptionFor the controller

- 25°C (- 13°F) to + 55°C (131°F)StandardComplete robot during trans-portation and storage

up to + 70°C (158°F)StandardFor short periods (not exceed-ing 24 hours)i At low environmental temperature < 10o C is, as with any other machine, a warm-up phase is

recommended to be run with the robot. Otherwise there is a risk that the robot stops or run withlower performance due to temperature dependent oil- and grease viscosity.

Relative humidity

Relative humidityDescription

Max. 95% at constant temperatureComplete robot during operation, transportation andstorage



1 Description1.3.2 Operating requirements

1.3.3 Mounting the manipulator

Maximum load IRB 2400/10/16Maximum load in relation to the base coordinate systemFloor Mounted

Max. load (emergency stop)Endurance load (in operation)Force

±2600 N±2000 NForce xy

+4100 ±1900 N+4100 ±1400 NForce z

±4000 Nm±3400 NmTorque xy

±900 Nm±550 NmTorque z

Suspended

Max. load (emergency stop)Endurance load (in operation)Force

±2600 N±2000 NForce xy

-4100 ±1900 N-4100 ±1400 NForce z

±4000 Nm±3400 NmTorque xy

±900 Nm±550 NmTorque z



1 Description1.3.3 Mounting the manipulator

A

D

C

B

xx1100000547

Torquexy (Txy)A

Force z (Fz)B

Force xy (Fxy)C

Torque z (Tz)D

Note regarding Mxy and FxyThe bending torque (Mxy) can occur in any direction in the XY-plane of the basecoordinate system. The same applies to the transverse force (Fxy).

Continues on next page18 Product specification - IRB 2400

3HAC042195-001 Revision: R© Copyright 2004-2021 ABB. All rights reserved.

1 Description1.3.3 Mounting the manipulatorContinued

Fastening holes robot base

21

02

80

B

A

A

260 260

(A)

Z

B

(B)

(C)

X

Y

48

Ø 0.5D = 18.5

B - B

D = 18.5 (2x)

48

20

Ø 0.25 D = 35 H8 (2x)+0.039

-0

A - A

xx1400002065



1 Description1.3.3 Mounting the manipulator

Continued

1.4 Calibration and references

1.4.1 Calibration methods

OverviewThis section specifies the different types of calibration and the calibrationmethodsthat are supplied by ABB.The original calibration data delivered with the robot is generated when the robotis floor mounted. If the robot is not floor mounted, then the robot accuracy couldbe affected. The robot needs to be calibrated after it is mounted.More information is available in the product manual.

Types of calibration

Calibration methodDescriptionType of calibration

Calibration PendulumThe calibrated robot is positioned at calibrationposition.

Standard calibration

Standard calibration data is found on the SMB(serial measurement board) or EIB in the robot.For robots with RobotWare 5.04 or older, thecalibration data is delivered in a file, calib.cfg,supplied with the robot at delivery. The fileidentifies the correct resolver/motor positioncorresponding to the robot home position.

CalibWareBased on standard calibration, and besidespositioning the robot at synchronization posi-tion, the Absolute accuracy calibration alsocompensates for:

• Mechanical tolerances in the robotstructure

• Deflection due to loadAbsolute accuracy calibration focuses on pos-itioning accuracy in the Cartesian coordinatesystem for the robot.

Absolute accuracycalibration (option-al)

Absolute accuracy calibration data is foundon the SMB (serial measurement board) in therobot.For robots with RobotWare 5.05 or older, theabsolute accuracy calibration data is deliveredin a file, absacc.cfg, supplied with the robot atdelivery. The file replaces the calib.cfg file andidentifies motor positions as well as absoluteaccuracy compensation parameters.A robot calibrated with Absolute accuracy hasa sticker next to the identification plate of therobot.To regain 100% Absolute accuracy perform-ance, the robot must be recalibrated for abso-lute accuracy after repair or maintenance thataffects the mechanical structure.

xx0400001197



1 Description1.4.1 Calibration methods

Calibration methodDescriptionType of calibration

Wrist OptimizationOptimization of TCP reorientation perform-ance. The purpose is to improve reorientationaccuracy for continuous processes like weld-ing and gluing.

Optimization

Wrist optimization will update standard calib-ration data for axes 4 and 5.

Brief description of calibration methods

Calibration Pendulum methodCalibration Pendulum is a standard calibration method for calibration of all ABBrobots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II• Reference calibration

The calibration equipment for Calibration Pendulum is delivered as a completetoolkit, including the Operating manual - Calibration Pendulum, which describesthe method and the different routines further.

Wrist Optimization methodWrist Optimization is a method for improving reorientation accuracy for continuousprocesses like welding and gluing and is a complement to the standard calibrationmethod.The following routines are available for the Wrist Optimization method:

• Wrist OptimizationThe actual instructions of how to perform the calibration procedure and what todo at each step is given on the FlexPendant. You will be guided through thecalibration procedure, step by step.

CalibWare - Absolute Accuracy calibrationThe CalibWare tool guides through the calibration process and calculates newcompensation parameters. This is further detailed in the Applicationmanual - CalibWare Field.If a service operation is done to a robot with the option Absolute Accuracy, a newabsolute accuracy calibration is required in order to establish full performance.For most cases after replacements that do not include taking apart the robotstructure, standard calibration is sufficient.



1 Description1.4.1 Calibration methods

Continued

1.4.2 Fine calibration

GeneralFine calibration is made using the Calibration Pendulum, see Operatingmanual - Calibration Pendulum.

(A)

(B)

(C)(D)(E)

(F)

xx1100000570


Axis 2BAxis 1A

Axis 4DAxis 3C

Axis 6FAxis 5E

Calibration

PositionCalibration

All axes are in zero positionCalibration of all axes

Axis 1 and 2 in zero positionCalibration of axis 1 and 2

Axis 3 to 6 in any position

Axis 1 in zero positionCalibration of axis 1

Axis 2 to 6 in any position



1 Description1.4.2 Fine calibration

1.4.3 Absolute Accuracy calibration

PurposeAbsolute Accuracy is a calibration concept that improves TCP accuracy. Thedifference between an ideal robot and a real robot can be several millimeters,resulting frommechanical tolerances and deflection in the robot structure.AbsoluteAccuracy compensates for these differences.Here are some examples of when this accuracy is important:

• Exchangeability of robots• Offline programming with no or minimum touch-up• Online programming with accurate movement and reorientation of tool• Programming with accurate offset movement in relation to eg. vision system

or offset programming• Re-use of programs between applications

The option Absolute Accuracy is integrated in the controller algorithms and doesnot need external equipment or calculation.

Note

The performance data is applicable to the corresponding RobotWare version ofthe individual robot.

xx1100000571

What is includedEvery Absolute Accuracy robot is delivered with:

• compensation parameters saved on the robot’s serial measurement board• a birth certificate representing the Absolute Accuracymeasurement protocol

for the calibration and verification sequence.A robot with Absolute Accuracy calibration has a label with this information on themanipulator.



1 Description1.4.3 Absolute Accuracy calibration

Absolute Accuracy supports floor mounted, wall mounted and ceiling mountedinstallations. Compensation parameters saved in the robot’s serial measurementboard differ depending on which Absolute Accuracy option is selected.

When is Absolute Accuracy being usedAbsolute Accuracy works on a robot target in Cartesian coordinates, not on theindividual joints. Therefore, joint based movements (e.g. MoveAbsJ) will not beaffected.If the robot is inverted, the Absolute Accuracy calibration must be performed whenthe robot is inverted.

Absolute Accuracy activeAbsolute Accuracy will be active in the following cases:

• Any motion function based on robtargets (e.g. MoveL) and ModPos onrobtargets

• Reorientation jogging• Linear jogging• Tool definition (4, 5, 6 point tool definition, room fixed TCP, stationary tool)• Work object definition

Absolute Accuracy not activeThe following are examples of when Absolute Accuracy is not active:

• Any motion function based on a jointtarget (MoveAbsJ)• Independent joint• Joint based jogging• Additional axes• Track motion

Note

In a robot system with, for example, an additional axis or track motion, theAbsolute Accuracy is active for the manipulator but not for the additional axis ortrack motion.

RAPID instructionsThere are no RAPID instructions included in this option.

Production dataTypical production data regarding calibration are:

Positioning accuracy (mm)Robot

% Within 1 mmMaxAverage

1000.700.30IRB 2400/10IRB 2400/16



1 Description1.4.3 Absolute Accuracy calibrationContinued

1.5 Load diagrams

1.5.1 Introduction to load diagrams

Information

WARNING

It is very important to always define correct actual load data and correct payloadof the robot. Incorrect definitions of load data can result in overloading of therobot.If incorrect load data is used, and/or if loads outside the load diagram are used,the following parts can be damaged due to overload:• motors• gearboxes• mechanical structure

WARNING

In RobotWare, the service routine LoadIdentify can be used to determine correctload parameters. The routine automatically defines the tool and the load. SeeOperating manual - IRC5 with FlexPendant, for detailed information.

WARNING

Robots running with incorrect load data and/or with loads outside the loaddiagram, will not be covered by robot warranty.

GeneralThe load diagrams include a nominal payload inertia, J0 of 0.040 kgm2 for IRB2400/10 and 0.060 kgm2 for IRB 2400/16 (also with extended load diagram). Atdifferent moment of inertia the load diagram will be changed. For robots that areallowed tilted, wall or inverted mounted, the load diagrams as given are valid andthus it is also possible to use RobotLoad within those tilt and axis limits.

Control of load case with RobotLoadTo verify a specific load case, use the RobotStudio add-in RobotLoad.The result from RobotLoad is only valid within the maximum loads and tilt angles.There is no warning if the maximum permitted arm load is exceeded. For over-loadcases and special applications, contact ABB for further analysis.



1 Description1.5.1 Introduction to load diagrams

Load diagrams

IRB 2400/10



1 Description1.5.1 Introduction to load diagramsContinued

IRB 2400/16



1 Description1.5.1 Introduction to load diagrams

Continued

IRB 2400/16 Extended load diagramBelow is a extended load diagram for IRB 2400/16, payload 20 kg.No extra load on wrist.

85



1 Description1.5.1 Introduction to load diagramsContinued

1.5.2 Maximum load and moment of inertia for full and limited axis 5 movement

Note

Total load given as: Mass in kg, center of gravity (Z and L) in meter and momentof inertia (Jox Joy Joz) in kgm2 . L=sqr(x2 + y2).

Full movement of axis 5 (±115o)

Maximum moment of interiaRobot typeAxis

Ja5 = Load x ((Z + 0,0852 + L2 ) + max (J0x, J0y) ≤ 1.15 kgm2IRB 2400/105

Ja6 = Load x L2 + J0Z ≤ 0.70 kgm2IRB 2400/106

Maximum moment of interiaRobot typeAxis

Ja5 = Load x ((Z + 0,0852 + L2 ) + max (J0x, J0y) ≤ 1.85 kgm2IRB 2400/165

Ja6 = Load x L2 + J0Z ≤ 1.05 kgm2IRB 2400/166



1 Description1.5.2 Maximum load and moment of inertia for full and limited axis 5 movement

1.5.3 Wrist torque

Maximum torque due to payloadThe table below shows the maximum permissible torque due to payload:

Note

The wrist torque values are for reference only, and should not be used forcalculating permitted load offset (position of center of gravity) within the loaddiagram, since those also are limited by main axes torques as well as dynamicloads. Furthermore, arm loads will influence the permitted load diagram. To findthe absolute limits of the load diagram, use the RobotStudio add-in RobotLoad.

Max torque valid atload

Max wrist torqueaxis 6

Max wrist torqueaxis 4 and 5

Robot type

10 kg9.81 Nm20.6 NmIRB 2400/10

16 kg15.7 Nm33.0 NmIRB 2400/16



1 Description1.5.3 Wrist torque

1.6 Mounting equipment

1.6.1 Information about mounting equipment

Mounting equipmentThe robot is supplied with tapped holes on the upper arm and on the base formounting extra equipment.

IRB 2400/10 and IRB 2400/16

40

0

300

35

70

65 177M8 (3x) 14

A A110

25

100

200

300 450

D=240

(B)

A - A

M5 (2x)

22

43

(C)

78 90

38o

M8 (3x)

C - C

120o (3x)

D=50

150

(D)

B

B

C

C

(A)

M8 (3x)

120o (3x)

B - B

38o

M6 (2x) 12

7.5

16 R=92

16 R=77

xx1100000577

Max loadPos

The rear side of the manipulatorA



1 Description1.6.1 Information about mounting equipment

Max loadPos

Max. 2 kgB

Max. 10 kgC

Max. 35 kg totalD

IRB 2400/16 with payload 20 kg

30

0

100

35

70

65 177

M8 (3x)14

A A

100

200

A - A (D)

90

38o

M8 (3x) R=77

16

C - C

120o (3x)

D=50

150

(C)

B

B

C

C

(B)

M8 (3x) R=9216

120o (3x)

B - B

38o

(A)

DescriptionPos

No extra load on wristA

The rear side of the manipulatorB

Max. 35 kg totalC

Max. 10 kgD



1 Description1.6.1 Information about mounting equipmentContinued

Note

Maximum loads must never be exceeded!

Fastener qualityWhen fitting tools on the tool flange, only use screws with quality 12.9. For otherequipment use suitable screws and tightening torque for your application.

IRB 2400/10 and IRB 2400/16

7

D=

31

,5

D=6+0.012-0

M6 (6x)

60

o

30o

A - A

A

A

R=25

Ø 0.05 B

D=

63

h8

B

5x

H7, min 8

H8

+0

.03

9-0

+0 -0

.04

6

10

xx1100000580



1 Description1.6.1 Information about mounting equipment

Continued

1.7 Maintenance and troubleshooting

GeneralThe robot requires only minimum maintenance during operation. It has beendesigned 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.

MaintenanceThemaintenance intervals depend on the use of the robot, the requiredmaintenanceactivities also depends on selected options. For detailed information onmaintenanceprocedures, see Maintenance section in the Product Manual.



1 Description1.7 Maintenance and troubleshooting

1.8 Robot motion

Introduction to robot motion

IRB 2400/10 and IRB 2400/16The working area is the same for both floor and inverted mounting.For wall mounted 10 kg version axis 1 is limited to ±30o .

Range of movementType of motionAxis

+ 180° to - 180°Rotation Motion1

+ 110° to - 100°Arm motion2

+ 65° to - 60°Arm motion3

+ 200° to - 200° (Unlimited as optional)Rotation Motion4

+ 120° to - 120°Bend motion5

+ 400° to - 400°Turn motion6+ 250 rev. i to - 250 rev. Max. ii

i rev. = Revolutionsii The default working range for axis 6 can be extended by changing parameter values in the software.

Option 610-1 "Independent axis" can be used for resetting the revolution counter after the axis hasbeen rotated (no need for "rewinding" the axis).

xx0200000160

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

Angle (degrees)Axis 3

Angle (degrees)Axis 2

Position (mm) ZPosition (mm) XPosition no (seefigure above)

0014558550

-60020413601

6506935412

-60110-11813513

18.3110-3024004

-60-100624-13505

65-1001036-536



1 Description1.8 Robot motion

Performance according to ISO 9283At rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISOtest plane, with all six axes in motion. Values in the table below are the averageresult of measurements on a small number of robots. The result may differdepending on where in the working range the robot is positioning, velocity, armconfiguration, from which direction the position is approached, the load directionof the arm system. Backlashes in gearboxes also affect the result.The figures for AP, RP, AT and RT are measured according to figure below.

xx0800000424


Programmed pathEProgrammed positionA

Actual path at program executionDMean position at programexecution

B

Max deviation from E to average pathATMean distance from pro-grammed position

AP

Tolerance of the path at repeatedprogram execution

RTTolerance of position B at re-peated positioning

RP

IRB 2400/16IRB 2400/10Description

0.030.03Pose repeatability, RP (mm)

0.030.03Pose accuracy, AP i (mm)

0.150.11Linear path repeatability, RT (mm)

0.410.33Linear path accuracy, AT (mm)

0.220.15Pose stabilization time, (PSt) to within 0.4 mm of theposition (s)i AP according to the ISO teset above, is the difference between the reached position (position

manually modified in the cell) and the average potition obtained during program executionThe above values are the range of average test results from a number of robots.

Velocity

Maximum axis speed

Axis 6Axis 5Axis 4Axis 3Axis 2Axis 1Robot type

450 °/s360 °/s360 °/s150 °/s150 °/s150 °/sIRB 2400/1090 °/s iii90 °/s ii90 °/s i



1 Description1.8 Robot motionContinued

Axis 6Axis 5Axis 4Axis 3Axis 2Axis 1Robot type

450 °/s360 °/s360 °/s150 °/s150 °/s150 °/sIRB 2400/16i For wall mounted 10 kg version.ii For wall mounted 10 kg version.iii For wall mounted 10 kg version.There is a supervision function to prevent overheating in applications with intensiveand frequent movements.

Stopping distance/timeStopping distance/time for emergency stop (category 0), program stop (category1)and at mains power supply failure at max speed, max stretched out and max load,categories according to EN 60204-1. All results are from tests on one moving axis.All stop distances are valid for floor mounted robot, without any tilting.

Main power failureCategory 1Category 0Robot type

BABABAAxis

0.6051.40.5543.30.5239.71IRB 2400/10

0.2523.70.1916.40.1813.52

0.2926.80.2418.70.2216.33

0.6756.10.8871.00.6248.41IRB 2400/16

0.2623.60.3628.80.2116.82

0.3532.30.4437.90.3024.93

Description

Stopping distance in degreesA

Stop time (s)B



1 Description1.8 Robot motion

Continued

1.9 Signals

Note

For more information of air and signals for extra equipment to upper arm, seeApplication interface on page 41.



1 Description1.9 Signals

2 Specification of variants and options2.1 Introduction to variants and options

GeneralThe different variants and options for the IRB 2400 are described in the followingsections. The same option numbers are used here as in the specification form.The variants and options related to the robot controller are described in the productspecification for the controller.



2 Specification of variants and options2.1 Introduction to variants and options

2.2 Manipulator

Variants

Handling capacity (kg) / Reach (m)IRB TypeOption

10/1.55IRB 2400/10435-7

16/1.55IRB 2400/16435-8

Manipulator color

NoteDescriptionOption

ABB Orange standard209-1

ABB White standard209-2

Standard colorABB Graphite White standard209-202

The robot is painted with the chosen RAL-color.209-

Note

Notice that delivery time for painted spare parts will increase for none standardcolors.

Protection

DescriptionOption

Standard287-4



2 Specification of variants and options2.2 Manipulator

DescriptionOption

Foundry Plus287-3The Foundry Plus option is designed for harsh environments where therobot is exposed to sprays of coolants, lubricants and metal spits thatare typical for die casting applications or other similar applications. Typ-ical applications are spraying insertion and part extraction of die-castingmachines, handling in sand casting and gravity casting, etc. (Please referto Foundry Prime for washing applications or other similar applications).Special care must be taken in regard to operational and maintenancerequirements for applications in foundry are as well as in other applica-tions areas. Please contact ABB Robotics Sales organization if in doubtregarding specific application feasibility for the Foundry Plus robot. TheFoundry Plus robot is painted with two-component epoxy on top of aprimer for corrosion protection. To further improve the corrosion protectionadditional rust preventive are applied to exposed and crucial areas, e.g.has the tool flange a special preventive coating. Although, continuoussplashing of water or other similar rust formation fluids may case rustattach on the robots unpainted areas, joints, or other unprotected surfaces.Under these circumstances it is recommended to add rust inhibitor to thefluid or take other measures to prevent potential rust formation on thementioned.The entire robot is IP67 compliant according to IEC 60529 -from base to wrist (except IRB 2400L, IP67 only on wrist and connectors),which means that the electrical compartments are sealed against waterand solid contaminants. Among other things all sensitive parts are betterprotected than the standard offer.Selected Foundry Plus features:- Improved sealing to prevent penetration into cavities to secure IP67- Additional protection of cabling and electronics- Special covers protecting cavities- Well-proven connectors- Rust preventives on screws, washers and unpainted/machined surfaces- Extended service and maintenance programThe Foundry Plus robot can be cleaned with appropriate washing equip-ment.The robot is labeled with “Foundry Plus” (IRB 2400F/10 and F/16).

Mounting position

DescriptionOption

Floor mounted224-1

Inverted224-2

Application interfaceAir supply and signals for extra equipment to upper arm.For connection of extra equipment on the manipulator, there are cables integratedinto the manipulator’s cabling, one FCI UT07 14 12SH44N connector and one FCIUT07 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.

DescriptionType

50 V, 250mA23Signals

250 V, 2 A10Power

Max. 8 bar, inner hose diameter 8 mm1Air




Continued

DescriptionOption

Integrated hose and cables for connection of extra equip-ment on the manipulator to the rear part of the upper arm.

218-8

Application interface connection to

DescriptionOption

16-1

The signals are connected to 12-pole screw terminals,Phoenix MSTB 2.5/12-ST-5.08, to the the controller.

16-1 Cabinet i

i Note! In a IRC5MultiMove application additional robots have no Control Module. The screw terminalswith internal cabling are then delivered separately to be mounted in the main robot Control Moduleor in another encapsulation, for example a PLC cabinet.

Connector kitDetached connectors, suitable to the connectors for the application interface andposition switches.The kit consists of connectors, pins and sockets.

DescriptionOption

For the connectors on the upper arm if application interface, option 218-8 or option 218-6.

431-1

For the connectors on the foot if connection to manipulator, option 16-2.239-1

Safety lamp

DescriptionOption

A safety lamp with an orange fixed light can be mounted on the manipu-lator.

213-1

The lamp is active in MOTORS ON mode.The safety lamp is required on a UL/UR approved robot.

Electronic Position Switches (EPS)The mechanical position switches indicating the position of the three main axesare replaced with electronic position switches for up to 7 axes, for increasedflexibility and robustness. For more detailed information, see Productspecification - Controller IRC5 and Application manual - Electronic PositionSwitches.

Working range limit - axis 1To increase the safety of the robot, the working range of axis 1 can be restriced.

DescriptionOption

Axis 128-1Two extra stops for restricting the working range. The stops can bemounted within the area from 50o to 140o . See figure below.



2 Specification of variants and options2.2 ManipulatorContinued

xx0500002105

Working range - axis 2To increase the safety of the robot, the working range of axis 2 can be restricted.

DescriptionOption

Axis 232-1Stop lugs for restricting the working area. The figure below illustrates themounting positions of the stops.

80°

50°

20°

40°

70°

xx1100000586

Working range - axis 3To increase the safety of the robot, the working range of axis 3 can be restricted.

DescriptionOption

Axis 334-1Equipment for electrically restricting the working range in increments of5o .




Continued

WarrantyFor the selected period of time, ABB will provide spare parts and labour to repairor replace the non-conforming portion of the equipment without additional charges.During that period, it is required to have a yearly Preventative Maintenanceaccording to ABB manuals to be performed by ABB. If due to customer restrainsno data can be analyzed in the ABB Ability service Condition Monitoring &Diagnostics for robots with OmniCore controllers, and ABB has to travel to site,travel expenses are not covered. The Extended Warranty period always starts onthe day of warranty expiration. Warranty Conditions apply as defined in the Terms& Conditions.

Note

This description above is not applicable for option Stock warranty [438-8]

DescriptionTypeOption

Standard warranty is 12months fromCustomer DeliveryDate or latest 18 months after Factory Shipment Date,whichever occurs first. Warranty terms and conditionsapply.

Standard warranty438-1

Standard warranty extended with 12 months from enddate of the standard warranty. Warranty terms and con-ditions apply. Contact Customer Service in case of otherrequirements.

Standard warranty + 12months

438-2



438-4



438-5

Standard warranty extended with 6 months from enddate of the standard warranty. Warranty terms and con-ditions apply.


438-6

Standard warranty extended with 30 months from enddate of the standard warranty. Warranty terms and con-ditions apply.


438-7

Maximum 6 months postponed start of standard war-ranty, starting from factory shipment date. Note that noclaims will be accepted for warranties that occurred be-fore the end of stock warranty. Standard warranty com-mences automatically after 6 months from FactoryShipment Date or from activation date of standard war-ranty in WebConfig.

Note

Special conditions are applicable, seeRoboticsWarrantyDirectives.

Stock warranty438-8



2 Specification of variants and options2.2 ManipulatorContinued

2.3 Positioners

GeneralRegarding positioners, see Product specification - IRBP /D2009, 3HAC038208-001.



2 Specification of variants and options2.3 Positioners

2.4 Track motion

Track motion type


For IRB 1600/2400 robot, with a travel length of 1.7 m.For for example material handling robot.

Not for AW1000-5

For IRB 1600/2400 robot, with a travel length of 1.7 m.For AW robot with Marthon-pac or Bobbin holder.

For AW1000-6

Additional travel length

DescriptionDescriptionOption

Chose additional travel length in meter, above the min.length under Track Motion Type.

(1-18) Add travellength

1001-1

The selection 1 adds 1m travel length, 2 adds 2m travellength and so on.......

Example of ordering a track motion RTT, with a requested travel length of 7.5 m:

xx1100000587

In this case, option 1000-5 specify a track motion with a travel length of 1.7 m,option 1000-5 adds 6 meters to that, ending up with total travel length of 7.7 m.



2 Specification of variants and options2.4 Track motion

2.5 Floor cables

2.5.1 Manipulator

Manipulator cable length

LengthsOption

7 m210-2

15 m210-3

22 m210-4

30 m210-5

Connection of Parallel communication

LengthsOption

7 m94-1

15 m94-2

30 m94-4



2 Specification of variants and options2.5.1 Manipulator

2.5.2 Positioner

Positioner cable 1

LengthsOption

7 m1067-1

10 m (Standard length)1067-2

15 m1067-3

Positioner cable 2

LengthsOption

7 m1068-1

10 m (Standard length)1068-2

15 m1068-3

Positioner cable type


Only available with one or two MTC250/500/750/2000/5000

Flexible1048-1

Weld return cable

LengthsOption

7 m1056-1

7 m x 21056-2

10 m1056-3

10 m x 21056-4

15 m1056-5

15 m x 21056-6

Return cable


Choose quantity, 1-2OKC T-connec-tion

1057-1



2 Specification of variants and options2.5.2 Positioner

2.6 Process

2.6.1 DressPack

Process module


Only available with one or two MTC250/500/750/2000/5000

Empty cabinetsmall

768-1

Empty cabinetlarge

768-2

WeldGuide III


Only together with ArsitoMig 4000i/5000i, MigRob andTPS power sources. Digital I/O or AD Combi I/O isneeded for WeldGuide functions. Requires optionWeldGuide MultiPass [815-2].

Basic958-1

Only together with ArsitoMig 4000i/5000i, MigRob andTPS power sources. Digital I/O or AD Combi I/O isneeded for WeldGuide functions. Requires optionWeldGuide MultiPass [815-2].

Advanced958-2

Installation kit


See Product Specification - Controller IRC5 with Flex-Pendant.

Installation kit715-1



2 Specification of variants and options2.6.1 DressPack

2.6.2 Process equipment

Torch service


ABB Torch Service Center.ABB TSC1037-1

ABB Torch cleaner.ABB TC961037-2

BullsEye stand alone.BullsEye1037-3

Torch service options


Extension pedestal for TSC/TC/BullsEye.Extensionpedes-tal

1038-1



2 Specification of variants and options2.6.2 Process equipment

2.7 User documentation

User documentationThe user documentation describes the robot in detail, including service and safetyinstructions.

Tip

All documents can be found via myABB Business Portal,www.abb.com/myABB.



2 Specification of variants and options2.7 User documentation

http://www.abb.com/myABB

3 Accessories3.1 Introduction to accessories

GeneralThere is a range of tools and equipment available, especially designed for themanipulator.

Basic software and software options for robot and PCFor more information, see Product specification - Controller IRC5 with FlexPendantand Product specification - Controller software IRC5.

Robot peripherals• Track Motion• Motor Units• Positioners



3 Accessories3.1 Introduction to accessories

IndexAAbsolute Accuracy, 23Absolute Accuracy, calibration, 21accessories, 53

Ccalibration

Absolute Accuracy type, 20standard type, 20

calibration, Absolute Accuracy, 21Calibration Pendulum, 22CalibWare, 20compensation parameters, 23

Ddocumentation, 51

EElectronic Position Switches, 42EPS, 42

Ffine calibration, 22

Iinstructions, 51

Mmanuals, 51

Ooptions, 39

Pproduct standards, 13

Ssafety standards, 13service instructions, 51standards, 13

ANSI, 13CAN, 13EN IEC, 13EN ISO, 13

standard warranty, 44stock warranty, 44

Uuser documentation, 51

Vvariants, 39

Wwarranty, 44



Index

ABB ABRobotics & Discrete AutomationS-721 68 VÄSTERÅS, SwedenTelephone +46 (0) 21 344 400

ABB ASRobotics & Discrete AutomationNordlysvegen 7, N-4340 BRYNE, NorwayBox 265, N-4349 BRYNE, NorwayTelephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.Robotics & Discrete AutomationNo. 4528 Kangxin HighwayPuDong DistrictSHANGHAI 201319, ChinaTelephone: +86 21 6105 6666

ABB Inc.Robotics & Discrete Automation1250 Brown RoadAuburn Hills, MI 48326USATelephone: +1 248 391 9000

abb.com/robotics

3HAC042195-001,Rev

R,en


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