ABB Robotics IRB 1100 Product Manual
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ABB Robotics IRB 1100 Product Manual

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Table of Contents

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IRB 1100

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Summary of Contents for ABB Robotics IRB 1100

  • Page 1 ROBOTICS Product manual IRB 1100...
  • Page 2 Trace back information: Workspace 20B version a15 Checked in 2020-06-01 Skribenta version 5.3.033...
  • Page 3 Product manual IRB 1100-4/0.475 IRB 1100-4/0.58 OmniCore Document ID: 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Mechanically restricting the working range ........... Electrical connections ..................3.5.1 Robot cabling and connection points ............3.5.2 Customer connections ................Start of robot in cold environments ..............Maintenance Introduction ...................... Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 6 Specification of maintenance intervals ............4.2.2 Maintenance schedule ................4.2.3 Expected component life ................. Cleaning activities ..................... 4.3.1 Cleaning the IRB 1100 ................Inspection activities ................... 4.4.1 Inspecting the information labels ..............4.4.2 Inspecting the robot for oil seepage ............4.4.3 Inspecting the robot cabling ..............
  • Page 7 Unit conversion ....................Screw joints ....................Weight specifications ..................Standard toolkit ....................Special tools ....................10 Spare parts 10.1 Spare part lists and illustrations ................Index Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    Product manual scope The manual covers all variants and designs of the IRB 1100. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Article number of Calibration tool box, Axis Calibration is changed from 3HAC062326-001 to 3HAC074119-001. • Installation of signal lamp is updated. • Supported controller OmniCore C90XT is added. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 11: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 12 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 13: How To Read The Product Manual

    Likewise, certain work methods or general information that is valid for several product models, can be illustrated with illustrations that show a different product model than the one that is described in the current manual. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 14 This page is intentionally left blank...

  • Page 15: Safety

    ABB is not liable for damages caused by the use of non-original spare parts and equipment. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 16: Requirements On Personnel

    The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the product manual. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 17: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 18 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 19: Safety Symbols On Manipulator Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 20 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 21 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 22 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 23 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 24 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 25: Robot Stopping Functions

    The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - OmniCore C30 • Product manual - OmniCore C90XT Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 26: Installation And Commissioning

    When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Electrical safety The mains power must be installed to fulfill national regulations. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 27 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 28: Operation

    Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 29: Maintenance And Repair

    Possible pressure build-up in gearbox Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 30 Unexpected movement of robot arm WARNING Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 31 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 32: Emergency Release Of The Robot Axes

    When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 33: Brake Testing

    3 Inspect and verify that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 34: Troubleshooting

    Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation, operation, maintenance, and repair. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 35: Decommissioning

    Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 36 This page is intentionally left blank...

  • Page 37: Technical Data

    Force in any direction in the XY plane Force in the Z plane Bending torque in any direction in the XY plane Bending torque in the Z plane Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 38 ±710N Force z +210 ±380 N +210 ±510 N Torque xy ±180 Nm ±330 Nm Torque z ±90 Nm ±140 Nm Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 39 The table shows the allowed operating conditions for the robot: Parameter Value Minimum ambient temperature +5°C (41°F) Maximum ambient temperature +45°C (113°F) Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 40 Protection classes, robot The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP40 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 41: Dimensions

    2 Technical data 2.2 Dimensions 2.2 Dimensions Main dimensions of IRB 1100-4/0.475 xx1800002606 Description Turning radius: R85 Turning radius: R109 Turning radius: R61 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 42 2 Technical data 2.2 Dimensions Continued Main dimensions of IRB 1100-4/0.58 xx1800002607 Description Turning radius: R85 Turning radius: R109 Turning radius: R61 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 43: Working Range

    2 Technical data 2.3 Working range 2.3 Working range Illustration, working range IRB 1100-4/0.475 This illustration shows the unrestricted working range of the robot. Pos 1 802.2 Pos 0 488.6 453.4 Pos 9 Pos 6 Pos 7 Pos 3 Pos 5...
  • Page 44 2 Technical data 2.3 Working range Continued Illustration, working range IRB 1100-4/0.58 This illustration shows the unrestricted working range of the robot. Pos 1 907.2 Pos 0 Pos 9 517.1 473.5 Pos 6 Pos 7 Pos 3 Pos 5 Pos 2 100.3...
  • Page 45 Axis 6 ±400° Default value. ±242 Maximum revolution value. The default working range for axis 6 can be extended by changing parameter values in the software. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 46: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 47: Installation And Commissioning

    Note If the IRB 1100 is connected to power, always make sure that the robot is connected to protective earth and a residual current device (RCD) before starting any installation work. For more information see: •...

  • Page 48: Unpacking

    If there are screws fixed to the pallet or foundation in the location shown in the figure, remove the screws and nuts. xx1900000105 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 49 3 Installation and commissioning 3.2.1 Transportation bracket (3HAC068893-001) Continued Action Note Remove the screws and washers. xx1900000102 xx1900000103 Remove the bracket. xx1900000104 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 50: Pre-Installation Procedure

    When these prerequisites are met, the robot can be taken to its installation site as described in section: On-site installation on page 53 Install required equipment, if any. • Installation of signal lamp (option) on page 66 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 51: Risk Of Tipping/Stability

    Shipping and transportation position This figure shows the robot in its shipping position and transportation position. IRB 1100-4/0.475 41.4° 16.5° xx1900000106 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 52 How to use the transportation bracket is described further in Transportation bracket (3HAC068893-001) on page WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 53: On-Site Installation

    When the robot is inverted, grasp the robot with one hand supporting at the housing and the other hand holding the base. xx1800002446 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 54 Be careful so that the robot does not bump into something while lifting and transporting. It could damage the robot. Secure the robot on a workbench according to section Orienting and securing the robot on page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 55: Lifting And Rotating A Suspended Mounted Robot

    How to lift and turn the robot to a suspended position: Contact ABB for more information. How to lift and turn the robot into position for wall position: Contact ABB for more information. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 56: Manually Releasing The Brakes

    Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 57 Use the brake releasing button as de- scribed in Releasing the brakes on page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 58: Orienting And Securing The Robot

    Hole con- figuration, base on page CAUTION The weight of the IRB 1100 robot is 21.1 kg All lifting accessories used must be sized accord- ingly. CAUTION When the robot is put down after being lifted or transported, there is a risk of it tipping, if not properly secured.
  • Page 59 + 0.012 4x M12 4x M12 6 H7 6 H7 11.5 11.5 + 0.012 + 0.012 4x R16 4x R16 6 H7 6 H7 xx1800002448 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 60: Setting The System Parameters For A Suspended Or A Tilted Robot

    If the robot is mounted on a wall (rotated around the x-axis), then the robot base frame and the system parameter Gravity Alpha must be redefined. The value of Gravity Alpha should then be ±π/2 (±1.570796). Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 61 Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Wall mounted 90° 1.570796 Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 62 Pos 1 Floor mounted Pos 2 Mounting angle 45° (Tilted) Pos 3 Mounting angle 90° (Wall) Pos 4 Mounting angle 180° (Suspended) Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 63 90° (Wall) 1.570796 -90° (Wall) -1.570796 Note For suspended robots (180°), it is recommended to use Gravity Beta instead of Gravity Alpha. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 64 Robot, in the topic Motion. The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 65: Loads Fitted To The Robot, Stopping Time And Braking Distances

    The loads must be defined in the software. Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 66: Installation Of Signal Lamp (Option)

    Further information about how to set up I/O system may be found in Technical reference manual - System parameters. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 67: Fitting Equipment On The Robot (Robot Dimensions)

    3 Installation and commissioning 3.3.7 Fitting equipment on the robot (robot dimensions) 3.3.7 Fitting equipment on the robot (robot dimensions) Robot dimensions Dimensions IRB 1100-4/0.475 The figure shows the dimension of the IRB 1100-4/0.475. xx1800002606 Description Turning radius: R85 Turning radius: R109...
  • Page 68 3 Installation and commissioning 3.3.7 Fitting equipment on the robot (robot dimensions) Continued Description Turning radius: R61 Dimensions IRB 1100-4/0.58 The figure shows the dimension of the IRB 1100-4/0.58. xx1800002607 Description Turning radius: R85 Turning radius: R109 Turning radius: R61...
  • Page 69 Maximum allowed arm load depends on center of gravity of arm load and robot payload. Holes for fitting extra equipment (4x) M3 x6 (4x) M4x6 (4x) M5x10 xx1800002449 IRB 1100-4/0.475 IRB 1100-4/0.58 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 70 3 Installation and commissioning 3.3.7 Fitting equipment on the robot (robot dimensions) Continued (2x) M4 (4x) M3 (2x) M4 xx1800002450 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 71 563. Fastener quality Use suitable screws and tightening torque for your application, screws with quality class 12.9 are recommended. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 72: Restricting The Working Range

    The working range of the following axes may be restricted: Axis Mechanical restric- Software restriction tion Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 73: Mechanically Restricting The Working Range

    Only axis 1 has a replacable mechanical stop. xx1800002452 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...

  • Page 74: Electrical Connections

    Robot cable, power Power cable length Article number Power cable 3 m 3HAC061139-001 Power cable 7 m 3HAC061139-002 Power cable 15 m 3HAC061139-003 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 75 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1800002453 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 76 CP/CS cable length Article number 3HAC067449-001 3HAC067449-002 15 m 3HAC067449-003 Customer cables - Ethernet floor cable (option) Ethernet floor cable length Article number 3HAC067447-002 15 m 3HAC067447-003 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 77: Customer Connections

    Max. 6 bar Inner hose diameter 4 mm The connector has 12 pins. Only pins 1 to 8 are available for use. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 78 Always remember to refit the protection covers after removing them. xx1900000132 CP/CS or Ethernet connector protection covers SMB connector protection cover Air hose connector protection covers Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 79: Start Of Robot In Cold Environments

    60, 60 v600 (600 mm/s) 5 Work cycles 100, 100 v1000 (1000 mm/s) More than 5 Work cycles 100, 100 Max. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 80 If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 81: Maintenance

    Note If the IRB 1100 is connected to power, always make sure that the IRB 1100 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: •...

  • Page 82: Maintenance Schedule And Expected Component Life

    4.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 1100: • Calendar time: specified in months regardless of whether the system is running or not.

  • Page 83: Maintenance Schedule

    Expected component life on page 84 Maintenance schedule Maintenance activities Reference Cleaning the robot Cleaning the IRB 1100 on page 85 Check for abnormal wear or Inspecting the robot contamination. Inspecting the information labels Inspecting the information labels...

  • Page 84: Expected Component Life

    Examples of "extreme usage" in regard to movement: press tending, very severe palletizing applications, major use of axis 1 movement and major use of bending backwards of axis 3. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 85: Cleaning Activities

    4.3.1 Cleaning the IRB 1100 General To secure high uptime it is important that the IRB 1100 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the IRB 1100.
  • Page 86 4 Maintenance 4.3.1 Cleaning the IRB 1100 Continued Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: •...

  • Page 87: Inspection Activities

    Read manual label, also specifying warning labels Rating label, CE label and AbsAcc label Calibration label Required tools and equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 88 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare parts on page 609. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 89: Inspecting The Robot For Oil Seepage

    Check the points of oil seepage, especially the seal lips and cover edges of the robot, regularly. If oil accumulation is observed, wipe it clean softly with a lint-free cloth to prevent oil dropping. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 90: Inspecting The Robot Cabling

    Look for abrasions, cuts or crush damage. Replace the cabling if wear or damage is detected. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 91: Inspecting Timing Belts

    It is recommended to inspect the axis-1 and axis-4 timing belts when replacing the motors. The timing belts are located as shown in the figures. Axis Location xx1800002457 xx1800002458 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 92 4 Maintenance 4.4.4 Inspecting timing belts Continued Axis Location xx1800002459 xx1800002460 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 93 Other tools and procedures may be required if the spare part needs to be replaced. These are specified in the replacement procedure. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 94 Use an acoustic tensiometer to measure Timing belt tension on page the timing belt tension. If the belt has no tension, adjust it! Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 95: Lubricating Activities

    4.5.1 Lubricating the cable package Location of the cable package The IRB 1100 main cable package has two segments, upper and lower. Inside the swing there is a division point. The cable packages are located as shown in the figure.
  • Page 96 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have con- tacting area with the cable package. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 97: Replacing/Changing Activities

    The battery pack is located as shown in the figure. xx1800002463 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 98 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1800003288 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 99 • SMB.J2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002468 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 100 ESD on page Disconnect the battery cable. xx1800002469 Remove the battery pack by cutting the cable strap. xx1800002470 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 101 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 102 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 103: Repair

    Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 1100, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 104: General Procedures

    Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 105: Mounting Instructions For Sealings

    Do not try to grind or polish the shaft surface to get rid of the defect. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 106 Mount the sealing correctly with a mounting tool. Never hammer directly on the sealing as this may result in leakage. xx2000000072 A Gap Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 107 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 108: Cut The Paint Or Surface On The Robot Before Replacing Parts

    Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 109: Cable Harness

    5.3 Cable harness 5.3 Cable harness General The IRB 1100 main cable package has two segments, upper and lower. Inside the swing there is a division point. The lower cable package runs from the base and up through into the swing. The upper cable package runs from the swing, up through the lower arm, into the housing and then into the wrist.

  • Page 110: Replacing The Upper Cable Package

    The upper cable package is located as shown in the figure. xx1800002466 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 111 1100 to be fitted to the tool flange during calibration of axis 6. 24 VDC power supply Used to release the motor brakes. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 112 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 113 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (IRB 1100-4/0.475) /95° (IRB 1100-4/0.58) • Axis 3: -20° (IRB 1100-4/0.475)/ -6° (IRB 1100-4/0.58) • Axis 4: 0°...
  • Page 114 Snap loose and remove the female head of the connector from the connector plate. xx1800002491 Remove the swing cover. xx1800002492 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 115 Be aware of the motor cabling. The motor cannot be removed completely until the connector is xx1800003603 disconnected, as shown in following step. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 116 Snap loose and remove the female head of the connectors from the connector plate. xx1800002498 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 117 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Disconnect the air hoses from the Y-shaped con- nectors. xx1800002500 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 118 Be aware of the cabling that is attached to the cover! The cover can not be removed completely until the connectors are disconnected, as shown in following steps. xx1800002944 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 119 • J5.C1 xx1800002947 For robots with Ethernet cabling J5.C2 connector assembly tool: - Disconnect the connector J5.C2 using the tool. xx1800002948 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 120 Access the connector FB5 from the process hub and disconnect the connector. xx1800002950 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 121 Removing the axis-6 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 122 Loosening the cable package from axis-4 gearbox Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 123 Separating the upper cable harness from the axis-2 gearbox Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 124 The connector plate cannot be removed completely until the connectors are re- move from the plate, as shown in following step. xx1800003004 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 125 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the lower arm cover. xx1800003007 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 126 Pay attention not to scratch the casting or damage the pad. xx1800003604 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 127 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the housing cover. xx1800003011 Disconnect the motor connectors. • • xx1800003012 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 128 Pulling out the upper cable harness Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 129 5.3.1 Replacing the upper cable package Continued Action Note Pull out the upper cable harness from the robot in the direction shown in the figure. xx1800003015 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 130 Wrap the connectors with the masking tape. gearbox. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1800003017 xx1800003601 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 131 Surfaces to be paralleled are shown in the following figures. xx1800003019 xx1800003020 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 132 Valid for IRB 1100-4/0.58 Plug screw: 3HAC064146-001 Refit the plug screw and washer on the extender Tightening torque: 2 Nm unit. xx1800003000 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 133 Remember to refit the lower arm support and xx1800003016 swing support after the cable package is inserted to place. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 134 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 135 Check the cooling pad. Cooling pad for axis-3 and -4 mo- tors: 3HAC071021-001 Replace if damaged. xx1800003604 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 136 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003022 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 137 21.7-23.94 N (for reference enced force. only) Initial referenced force for new belt: 31-34.2 N xx1900000028 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 138 Slide the connectors into the connector plate and reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx1800003005 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 139 Tightening torque: 0.6 Nm xx1800003006 Refit the connector plate. Screw: M3x12 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.4 Nm xx1800003004 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 140 Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side. xx1800003023 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 141 8.96-9.8 N (for reference only) enced force. Initial referenced force for new belt: 12.8-14 xx1900000026 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 142 Note Reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx1800003025 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 143 For robots with safety lamp (option 3308-1) Reconnect the connector J5.UL and place the connector behind the air hose connectors. xx1800002946 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 144 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 145 Reconnect the connectors. • J2.C1 • J2.C2 See the number markings on the connectors for help to find the corresponding connector. xx1800002501 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 146 Check the cooling pad. Cooling pad for axis-1 and -2 mo- tors: 3HAC071020-001 Replace if damaged, as shown in the following step. xx1800003603 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 147 Refit the screws and washers. Screw: M4x16 12.9 Gleitmo 603+Geomet 500 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800002494 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 148 68.18-75.04 N (for reference enced force. only) Initial referenced force for new belt: 97.4-107.2 N xx1900000029 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 149 Remove the adjustment screw from the motor. xx1900000010 Reconnect the connector. • See the number markings on the connectors for help to find the corresponding connector. xx1800002495 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 150 Refit the connector plate. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.8 Nm xx1800002489 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 151 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 152: Replacing The Lower Cable Package

    The lower cable package is located as shown in the figure. xx1800002465 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 153 If no data is found related to standard calibration, manual calibration is used as default. Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 154 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Jog all axes to zero position. xx1800003288 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 155 Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are re- move from the plate. xx1800002489 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 156 Disconnect the connector. • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002495 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 157 Remove the timing belt from its groove on the motor. xx1800002496 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 158 • J2.MP3,4,5/6 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002497 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 159 Disconnecting the air hoses, CP/CS cabling and Ethernet cabling (if equipped) Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 160 Disconnecting the SMB cabling Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 161 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C ©...
  • Page 162 Opening the connector interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 163 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 164 Remove the base bottom cover. xx1800003035 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx1800003057 Disconnect the earth cable. xx1800003036 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 165 Remove the female header of the J1M.BR connect- or from the connector plate. xx1800003039 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 166 Separating the cable package from the base Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 167 Pulling out the cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 168 Pull out the lower cable package from the base. xx1800003045 Remove the pulley cover from the lower cable package. xx1800003046 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 169 Action Note Refit the pulley cover to the lower cable package. xx1800003046 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 170 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 171 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 172 The cable protection tube surface is com- pletely parallel with the pulley cover at one side and with the flange at the other side. xx1800003063 xx1800003049 xx1800003050 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 173 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 174 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 175 Tightening torque: 1.2 Nm Valid for cabling with rear inter- face xx1800003034 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 176 Note Tighten the brake release button using the tool. brake release button assembly tool, included in the special toolkit 3HAC071022-001 xx1800003040 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 177 Reconnect the floor cable together with the con- Screw: M3x8 12.9 Gleitmo nector plate. 603+Geomet 500 (2 pcs) Tightening torque: 0.8 Nm xx1800003037 xx1800003036 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 178 Valid for cabling with bottom interface (option Screw: M3x8 12.9 Gleitmo 3309-1) 603+Geomet 500 (6 pcs) Refit the rear cover. Tightening torque: 1.2 Nm xx1800003057 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 179 Securing the robot to the foundation Action Note CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
  • Page 180 Check the cooling pad. Cooling pad for axis-1 and -2 mo- tors: 3HAC071020-001 Replace if damaged, as shown in the following step. xx1800003603 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 181 Refit the screws and washers. Screw: M4x16 12.9 Gleitmo 603+Geomet 500 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800002494 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 182 68.18-75.04 N (for reference enced force. only) Initial referenced force for new belt: 97.4-107.2 N xx1900000029 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 183 Remove the adjustment screw from the motor. xx1900000010 Reconnect the connector. • See the number markings on the connectors for help to find the corresponding connector. xx1800002495 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 184 Refit the connector plate. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.8 Nm xx1800002489 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 185 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 186: Replacing The Smb Unit

    The SMB unit is located as shown in the figure. xx1800002464 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 187 If no previous reference values exist, and routine on page 570. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 188 Disconnecting the SMB cabling Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 189 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 190 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 191 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 192 • SMB.P7 • SMB.J1 • SMB.J2 See the number markings on the connectors for help to find the corresponding connector. xx1800002468 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 193 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 194: Swing And Base

    The base is located as shown in the figure. xx1800002472 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 195 Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant. If no data is found related to standard calibration, manual calibration is used as default. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 196 Preparations before removing the base Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 197 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the swing support cover. xx1800002488 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 198 Snap loose and remove the female head of the connector from the connector plate. xx1800002491 Remove the swing cover. xx1800002492 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 199 Be aware of the motor cabling. The motor cannot be removed completely until the connector is xx1800003603 disconnected, as shown in following step. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 200 Disconnecting the connectors at the division point Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 201 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800002499 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 202 The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 203 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation.
  • Page 204 Opening the connector interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 205 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 206 Remove the base bottom cover. xx1800003035 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx1800003057 Disconnect the earth cable. xx1800003036 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 207 Remove the female header of the J1M.BR connect- or from the connector plate. xx1800003039 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 208 Separating the cable package from the base Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 209 Pulling out the cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 210 Removing the axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 211 Pay attention not to scratch the casting or damage the pad. xx1800003602 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 212 Separating the base from the swing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 213 Separate the base from the swing. CAUTION The axis-1 mechanical stop is accessible now. Put it aside for later refitting. xx1800003070 xx1800003071 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 214 (A) on the swing. Make sure the mechanical stop step pointed in the figure is fa- cing the swing when putting. xx1800003071 xx1800003619 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 215 Refitting the axis-1 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 216 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 217 Pay attention to the force application direction. xx1900000041 Secure the motor with the screws. Tightening torque: 3 Nm Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 218 Action Note Refit the pulley cover to the lower cable package. xx1800003046 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 219 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 220 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 221 The cable protection tube surface is com- pletely parallel with the pulley cover at one side and with the flange at the other side. xx1800003063 xx1800003049 xx1800003050 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 222 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 223 Refit the SMB cover to the base. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (6 pcs) Tightening torque: 1.2 Nm xx1800002467 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 224 Reconnect the connectors. • J1M.BR • • See the number markings on the connectors for help to find the corresponding connector. xx1800003054 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 225 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 226 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 227 Tightening torque: 1.2 Nm Valid for cabling with rear inter- face xx1800003034 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 228 Securing the robot to the foundation Action Note CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
  • Page 229 Check the cooling pad. Cooling pad for axis-1 and -2 mo- tors: 3HAC071020-001 Replace if damaged, as shown in the following step. xx1800003603 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 230 Refit the screws and washers. Screw: M4x16 12.9 Gleitmo 603+Geomet 500 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800002494 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 231 68.18-75.04 N (for reference enced force. only) Initial referenced force for new belt: 97.4-107.2 N xx1900000029 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 232 Remove the adjustment screw from the motor. xx1900000010 Reconnect the connector. • See the number markings on the connectors for help to find the corresponding connector. xx1800002495 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 233 Refit the connector plate. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.8 Nm xx1800002489 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 234 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 235: Replacing The Swing

    The swing is located as shown in the figure. xx1800002473 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 236 The robot is calibrated by either manual calibration or Axis Calibration at factory. Always use the same calibration method as used at the factory. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 237 Preparations before removing the swing Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 238 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the swing support cover. xx1800002488 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 239 Snap loose and remove the female head of the connector from the connector plate. xx1800002491 Remove the swing cover. xx1800002492 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 240 Be aware of the motor cabling. The motor cannot be removed completely until the connector is xx1800003603 disconnected, as shown in following step. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 241 Disconnecting the connectors at the division point Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 242 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800002499 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 243 The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 244 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation.
  • Page 245 Opening the connector interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 246 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 247 Remove the base bottom cover. xx1800003035 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx1800003057 Disconnect the earth cable. xx1800003036 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 248 Remove the female header of the J1M.BR connect- or from the connector plate. xx1800003039 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 249 Separating the cable package from the base Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 250 Pulling out the cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 251 Removing the axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 252 Pay attention not to scratch the casting or damage the pad. xx1800003602 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 253 Separating the base from the swing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 254 Separate the base from the swing. CAUTION The axis-1 mechanical stop is accessible now. Put it aside for later refitting. xx1800003070 xx1800003071 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 255 Separating the swing from the lower arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 256 (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002192 Separate the swing from the lower arm. xx1800003078 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 257 If the swing support is hard to closely fit to the lower arm, use a plastic hammer to knock on the swing support lightly. xx1800003076 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 258 Placing the axis-1 mechanical stop Action Note Check the axis-1 mechanical stop. Mechanical stop, axis 1: 3HAC061947-001 Replace if damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 259 Screw: M4x16 12.9 Gleitmo 603+Geomet 500 (13 pcs) Tightening torque: 4.4 Nm Note Pay attention to the screw and washer location. xx1800003069 xx1800003068 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 260 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley. xx1800003085 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 261 Do not tighten the screws yet. xx1800003065 Adjusting the axis-1 timing belt tension Action Note Use a handheld tensiometer hooking to the motor. xx1900000040 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 262 Action Note Refit the pulley cover to the lower cable package. xx1800003046 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 263 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 264 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 265 The cable protection tube surface is com- pletely parallel with the pulley cover at one side and with the flange at the other side. xx1800003063 xx1800003049 xx1800003050 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 266 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 267 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 268 Tightening torque: 1.2 Nm Valid for cabling with rear inter- face xx1800003034 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 269 Reconnect the connectors. • J1M.BR • • See the number markings on the connectors for help to find the corresponding connector. xx1800003054 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 270 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 271 Securing the robot to the foundation Action Note CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
  • Page 272 Securing the cable package to the swing Action Note Refit the cable bracket. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.8 Nm xx1800002499 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 273 Bend the motor signal cable back towards the swing support. xx1800003027 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 274 Install an M6x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000010 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 275 New belt:180-229 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 276 Reconnecting the connectors at the division point Action Note Insert the female header of the connectors to the connector plate. xx1800003029 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 277 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 278 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 279: Lower Arm

    The lower arm is located as shown in the figure. xx1800002474 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number Note Lower arm (IRB 1100-4/0.58)
  • Page 280 If no data is found related to standard calibration, manual calibration is used as default. Required consumables Consumable Article number Note Cable straps Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 281 Preparations before removing the lower arm Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 282 5.5.1 Replacing the lower arm Continued Action Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (IRB 1100-4/0.475) /95° (IRB 1100-4/0.58) • Axis 3: -20° (IRB 1100-4/0.475)/ -6° (IRB 1100-4/0.58) • Axis 4: 0° •...
  • Page 283 Snap loose and remove the female head of the connector from the connector plate. xx1800002491 Remove the swing cover. xx1800002492 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 284 Be aware of the motor cabling. The motor cannot be removed completely until the connector is xx1800003603 disconnected, as shown in following step. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 285 Snap loose and remove the female head of the connectors from the connector plate. xx1800002498 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 286 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Disconnect the air hoses from the Y-shaped con- nectors. xx1800002500 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 287 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800003002 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 288 • • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800003005 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 289 Remove the lower arm cover. xx1800003007 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003008 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 290 Removing the swing support Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 291 If the swing is hard to loosen from the housing, use a plastic hammer to knock on the swing lightly. xx1800003081 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 292 Pulling out the upper cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 293 Separating the lower arm from the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 294 During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002190 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 295 Route the cable package through the lower arm support. Refitting the axis-2 gearbox Action Note Refit the axis-2 gearbox. xx1800003083 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 296 Apply grease Castrol Molub-Alloy 777-1 NG to the inner surface of the lower arm, where contacts the bearing on the swing support. xx2000000058 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 297 Refitting the axis-3 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 298 Refit the screws and washers. Screw: M4x12 12.9 Gleitmo 603+Geomet 500 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800003009 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 299 Install an M4x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000009 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 300 New belt:113-143 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 301 Refit the cable bracket. Screw: M2.5x6 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.6 Nm xx1800003006 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 302 The air hoses with the same number connect to the same Y-shaped connector. xx1800002500 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 303 Refitting the axis-2 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 304 Bend the motor signal cable back towards the swing support. xx1800003027 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 305 Install an M6x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000010 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 306 New belt:180-229 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 307 Reconnecting the connectors at the division point Action Note Insert the female header of the connectors to the connector plate. xx1800003029 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 308 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 309 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 310: Housing, Extender Unit And Wrist

    The housing is located as shown in the figure. xx1800002475 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 311 If no data is found related to standard calibration, manual calibration is used as default. Required consumables Consumable Article number Note Cable straps Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 312 Preparations before removing the housing Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 313 5.6.1 Replacing the housing Continued Action Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (IRB 1100-4/0.475) /95° (IRB 1100-4/0.58) • Axis 3: -20° (IRB 1100-4/0.475)/ -6° (IRB 1100-4/0.58) • Axis 4: 0° •...
  • Page 314 • J5.C1 xx1800002947 For robots with Ethernet cabling J5.C2 connector assembly tool: - Disconnect the connector J5.C2 using the tool. xx1800002948 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 315 Access the connector FB5 from the process hub and disconnect the connector. xx1800002950 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 316 Removing the axis-6 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 317 Loosening the cable package from axis-4 gearbox Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 318 Disconnecting the axis-4 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 319 Separating the upper cable package from the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 320 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the lower arm support cover. xx1800003092 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 321 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003094 Remove the screws and washers. xx1800003095 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 322 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the pulley cover. xx1800003097 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 323 Contact ABB for more informa- tion. xx1900002191 Valid for IRB 1100-4/0.475 Separate the wrist from the housing. xx1800003075 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 324 The connector plate cannot be removed completely until the connectors are re- move from the plate, as shown in following step. xx1800003004 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 325 If the lower arm support is hard to loosen from the housing, use a plastic hammer to knock on the lower arm support lightly. xx1800003088 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 326 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003008 Remove the timing belt from its grooves on the motor and gearbox. xx1800003022 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 327 Removing the axis-3 gearbox Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 328 Remove the screws on the labyrinth sealing ring. xx1900001425 Remove the labyrinth sealing ring lightly and evenly. xx1900001417 Remove the screws. xx1800003284 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 329 Refit the axis-3 gearbox. xx1800003285 Secure with screws. Screw: M3x30 12.9 Gleitmo 603+Geomet 500 (12 pcs) Tightening torque: 1.8 Nm xx1800003284 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 330 Apply a little Loctite 243 to the screws and secure Screw: M3x4 (2 pcs) the labyrinth sealing ring with the screws. Tightening torque: 0.8 Nm xx1900001425 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 331 Screw: M5x16 12.9 Steel Black Oxide (5 pcs) Tightening torque: 8 Nm xx1800003088 Route the cable package through the lower arm support. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 332 Install an M4x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000009 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 333 New belt: 113-143 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 334 Refit the cable bracket. Screw: M2.5x6 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.6 Nm xx1800003006 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 335 Refit the the wrist to the housing. xx1800003075 Valid for IRB 1100-4/0.58 Refit the extender unit and wrist to the housing. xx1800003100 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 336 Refit the pulley cover. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (3 pcs) Tightening torque: 1.2 Nm xx1800003097 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 337 Use the motor fitting tool to fix the timing belt. axis-4 motor fitting tool, included in the special toolkit 3HAC071022- 001. xx1900000044 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 338 603+Geomet 500 (3 pcs) Washer, 3HAC064765-001 (3 pcs) Note Do not tighten the screws yet. xx1800003095 Remove the motor fitting tool. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 339 Fit an M3x25 eye bolt o the screw hole. xx1900000037 Use a handheld tensiometer hooking to the eye bolt. xx1900000038 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 340 Tightening torque: 1.4 Nm xx1800003094 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001 below the housing. Tightening torque: 2 Nm Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 341 Wrap the connectors with the masking tape. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1800003017 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 342 Surfaces to be paralleled are shown in the following figures. xx1800003019 xx1800003020 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 343 Valid for IRB 1100-4/0.58 Plug screw: 3HAC064146-001 Refit the plug screw and washer on the extender Tightening torque: 2 Nm unit. xx1800003000 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 344 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 345 Refitting the axis-6 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 346 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003024 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 347 New belt:90-114 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 348 If the cables are routed and secured incorrectly the cables can be damaged. Insert the cabling and connectors into the wrist. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 349 The air hoses with the same number connect to the same Y-shaped connector. xx1800002945 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 350 Refit the cover. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (4 pcs) Tightening torque: 1.2 Nm xx1800002944 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 351 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 352: Replacing The Extender Unit And Wrist

    5.6.2 Replacing the extender unit and wrist 5.6.2 Replacing the extender unit and wrist Location of the extender unit and wrist The IRB 1100-4/0.58 has an extender unit connecting the housing and wrist, which is located as shown in the figure. xx1800002476 The wrist is located as shown in the figure.
  • Page 353 Continued xx1800002477 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 354 Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant. If no data is found related to standard calibration, manual calibration is used as default. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 355 Preparations before removing the extender unit and wrist Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 356 5.6.2 Replacing the extender unit and wrist Continued Action Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (IRB 1100-4/0.475) /95° (IRB 1100-4/0.58) • Axis 3: -20° (IRB 1100-4/0.475)/ -6° (IRB 1100-4/0.58) • Axis 4: 0° •...
  • Page 357 • J5.C1 xx1800002947 For robots with Ethernet cabling J5.C2 connector assembly tool: - Disconnect the connector J5.C2 using the tool. xx1800002948 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 358 Access the connector FB5 from the process hub and disconnect the connector. xx1800002950 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 359 Removing the axis-6 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 360 Removing the axis-5 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 361 Remove the screws and washers. xx1800003294 Carefully lift out the motor. Remove the timing belt from its groove on the motor. xx1800003295 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 362 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 363 Separating the upper cable package from the housing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 364 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the lower arm support cover. xx1800003092 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 365 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003094 Remove the screws and washers. xx1800003095 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 366 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the pulley cover. xx1800003097 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 367 Contact ABB for more informa- tion. xx1900002191 Valid for IRB 1100-4/0.475 Separate the wrist from the housing. xx1800003299 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 368 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the screws. xx1800003300 Pull out the gearbox. xx1800003310 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 369 5 Repair 5.6.2 Replacing the extender unit and wrist Continued Separating the extender unit and wrist Notice that this procedure is valid for IRB 1100-4/0.58. Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off.
  • Page 370 Valid for IRB 1100-4/0.475 xx1800003313 Valid for IRB 1100-4/0.58 xx1800003312 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 371 Refit the the wrist to the housing. xx1800003075 Valid for IRB 1100-4/0.58 Refit the extender unit and wrist to the housing. xx1800003100 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 372 Refit the pulley cover. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (3 pcs) Tightening torque: 1.2 Nm xx1800003097 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 373 Use the motor fitting tool to fix the timing belt. axis-4 motor fitting tool, included in the special toolkit 3HAC071022- 001. xx1900000044 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 374 603+Geomet 500 (3 pcs) Washer, 3HAC064765-001 (3 pcs) Note Do not tighten the screws yet. xx1800003095 Remove the motor fitting tool. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 375 Fit an M3x25 eye bolt o the screw hole. xx1900000037 Use a handheld tensiometer hooking to the eye bolt. xx1900000038 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 376 Tightening torque: 1.4 Nm xx1800003094 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001 below the housing. Tightening torque: 2 Nm Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 377 Wrap the connectors with the masking tape. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1800003017 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 378 Surfaces to be paralleled are shown in the following figures. xx1800003019 xx1800003020 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 379 Valid for IRB 1100-4/0.58 Plug screw: 3HAC064146-001 Refit the plug screw and washer on the extender Tightening torque: 2 Nm unit. xx1800003000 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 380 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 381 Refitting the axis-5 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 382 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003292 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 383 New belt: 167-213 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 384 Refit the screws and washers. Screw: M3x12 12.9 Gleitmo 603+Geomet 500 (3 pcs) Note Do not tighten the screws yet. xx1800002996 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 385 Initial referenced force for new belt: 12.8-14 xx1900000026 Secure the motor with the screws. Tightening torque: 1.4 Nm xx1800002995 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 386 If the cables are routed and secured incorrectly the cables can be damaged. Insert the cabling and connectors into the wrist. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 387 The air hoses with the same number connect to the same Y-shaped connector. xx1800002945 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 388 Refit the cover. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (4 pcs) Tightening torque: 1.2 Nm xx1800002944 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 389 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 390: Motors

    The axis-1 motor is located as shown in the figure. xx1800002482 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 391 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 392 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 393 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation.
  • Page 394 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 395 Disconnecting axis-1 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 396 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800003042 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 397 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003064 Remove the screws and washers. xx1800003065 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 398 Check the cooling pad. Cooling pad for axis-1 and -2 mo- tors: 3HAC071020-001 Replace if damaged. xx1800003602 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 399 Refit the screws and washers. Screw: M4x16 12.9 Gleitmo 603+Geomet 500 (3 pcs) Washer, 3HAC063985-001 (3 pcs) Note Do not tighten the screws yet. xx1800003065 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 400 Securing the lower cable package to the base Action Note Refit the cable bracket. Screw: M2.5x6 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.6 Nm xx1800003042 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 401 Valid for cabling with bottom interface (option Screw: M3x8 Steel 8.8-A2F (7 pcs) 3309-1) Tightening torque: 1.2 Nm Refit the base adapter. xx1800003056 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 402 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 403 Securing the robot to the foundation Action Note CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
  • Page 404 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 405: Replacing The Axis-2 Motor

    The axis-2 motor is located as shown in the figure. xx1800002483 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 406 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 407 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 408 • J2.FB2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002490 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 409 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002493 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 410 Removing the cooling pad Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 411 Refitting the axis-2 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 412 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003028 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 413 Initial referenced force for new belt: 97.4-107.2 N xx1900000029 Secure the motor with the screws. Tightening torque: 3.5 Nm xx1800002493 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 414 Reconnecting the connector J2.FB2 Action Note Insert the female header of the J2.FB2 connector to the connector plate. xx1800002491 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 415 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 416 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 417: Replacing The Axis-3 Motor

    The axis-3 motor is located as shown in the figure. xx1800002484 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 418 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 419 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 420 • • Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800003005 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 421 Remove the lower arm cover. xx1800003007 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003008 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 422 Pay attention not to scratch the casting or damage the pad. xx1800003604 Remove the timing belt from its groove on the motor. xx1800003010 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 423 Orient the motor correctly and fit it into the lower Motor orientation: orient the motor arm. according to the figure below, in regard to the encircled motor con- nector. xx1800003021 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 424 Install an M4x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000009 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 425 New belt:113-143 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 426 Refit the cable bracket. Screw: M2.5x6 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.6 Nm xx1800003006 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 427 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 428: Replacing The Axis-4 Motor

    The xx is located as shown in the figure. xx1800002485 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 429 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 430 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 431 Removing the axis-4 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 432 Pay attention not to scratch the casting or damage the pad. xx1800003605 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 433 Check the cooling pad. Cooling pad for axis-3 and -4 mo- tors: 3HAC071021-001 Replace if damaged. xx1800003605 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 434 Make sure the motor flange does not press on the timing belt. xx1800003287 Install the timing belt to the motor pulley. xx1800003617 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 435 Action Note Remove the screw and washer below the housing. xx1900000036 Fit an M3x25 eye bolt o the screw hole. xx1900000037 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 436 Tightening torque: 1.4 Nm xx1800003094 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001 below the housing. Tightening torque: 2 Nm Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 437 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 438 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 439: Replacing The Axis-5 Motor

    The axis-5 motor is located as shown in the figure. xx1800002486 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 440 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 441 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 442 Disconnecting the axis-5 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 443 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003290 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 444 Refitting the axis-5 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 445 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul- leys. xx1800003292 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 446 New belt: 167-213 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 447 Apply grease to the cable package, cover all moving area of the package. Apply grease to the cover that has contacting area with the cable package. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 448 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 449: Replacing The Axis-6 Motor

    The xx is located as shown in the figure. xx1800002487 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 450 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 451 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 452 Disconnecting the axis-6 motor connectors Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 453 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002995 Remove the screws and washers. xx1800002996 Carefully lift out the motor. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 454 Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side. xx1800003023 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 455 8.96-9.8 N (for reference only) enced force. Initial referenced force for new belt: 12.8-14 xx1900000026 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 456 Note Reconnect the connectors. • • See the number markings on the connectors for help to find the corresponding connector. xx1800002994 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 457 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 458 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 459: Gearboxes

    The axis-1 gearbox is located as shown in the figure. xx1800002478 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 460 If no data is found related to standard calibration, manual calibration is used as default. Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 461 Preparations before removing the axis-1 gearbox Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 462 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the swing support cover. xx1800002488 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 463 Snap loose and remove the female head of the connector from the connector plate. xx1800002491 Remove the swing cover. xx1800002492 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 464 Be aware of the motor cabling. The motor cannot be removed completely until the connector is xx1800003603 disconnected, as shown in following step. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 465 Disconnecting the connectors at the division point Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 466 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable bracket. xx1800002499 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 467 The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 468 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. WARNING The robot is likely to be mechanically unstable if not secured to the foundation.
  • Page 469 Opening the connector interface plate Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 470 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Valid for cabling with bottom interface (option 3309-1) Remove the base adapter. xx1800003056 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 471 Remove the base bottom cover. xx1800003035 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx1800003057 Disconnect the earth cable. xx1800003036 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 472 Remove the female header of the J1M.BR connect- or from the connector plate. xx1800003039 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 473 Separating the cable package from the base Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 474 Pulling out the cable package Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 475 Removing the axis-1 motor Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 476 Pay attention not to scratch the casting or damage the pad. xx1800003602 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 477 Separating the base from the swing Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 478 Separate the base from the swing. CAUTION The axis-1 mechanical stop is accessible now. Put it aside for later refitting. xx1800003070 xx1800003071 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 479 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the screws. xx1800003073 Pull out the gearbox. xx1800003074 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 480 Placing the axis-1 mechanical stop Action Note Check the axis-1 mechanical stop. Mechanical stop, axis 1: 3HAC061947-001 Replace if damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 481 Screw: M4x16 12.9 Gleitmo 603+Geomet 500 (13 pcs) Tightening torque: 4.4 Nm Note Pay attention to the screw and washer location. xx1800003069 xx1800003068 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 482 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley. xx1800003085 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 483 Do not tighten the screws yet. xx1800003065 Adjusting the axis-1 timing belt tension Action Note Use a handheld tensiometer hooking to the motor. xx1900000040 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 484 Action Note Refit the pulley cover to the lower cable package. xx1800003046 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 485 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 486 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 487 The cable protection tube surface is com- pletely parallel with the pulley cover at one side and with the flange at the other side. xx1800003063 xx1800003049 xx1800003050 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 488 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 489 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 490 Tightening torque: 1.2 Nm Valid for cabling with rear inter- face xx1800003034 Valid for cabling with bottom inter- face (option 3309-1) xx1800003055 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 491 Reconnect the connectors. • J1M.BR • • See the number markings on the connectors for help to find the corresponding connector. xx1800003054 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 492 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 493 Securing the robot to the foundation Action Note CAUTION The IRB 1100 robot weighs 21.1 kg and can be lifted by one person. Raise the robot to standing and secure to the Attachment screws: M12x25 (robot foundation with the attachment screws and installation directly on foundation), washers.
  • Page 494 Securing the cable package to the swing Action Note Refit the cable bracket. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.8 Nm xx1800002499 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 495 Bend the motor signal cable back towards the swing support. xx1800003027 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 496 Install an M6x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000010 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 497 New belt:180-229 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 498 Reconnecting the connectors at the division point Action Note Insert the female header of the connectors to the connector plate. xx1800003029 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 499 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 500 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 501: Replacing The Axis-2 Gearbox

    The axis-2 gearbox is located as shown in the figure. xx1800002479 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 502 Fine calibration. All external cable ing flange is used for installation of the packages (DressPack) and tools calibration tool. must be removed from the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 503 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (IRB 1100-4/0.475) /95° (IRB 1100-4/0.58) • Axis 3: -20° (IRB 1100-4/0.475)/ -6° (IRB 1100-4/0.58) • Axis 4: 0°...
  • Page 504 • J2.FB2 Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx1800002490 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 505 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002493 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 506 Separating the upper cable harness from the axis-2 gearbox Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 507 Separating the swing from the lower arm Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 508 Move the lower arm aside a little to access the gearbox screws. Remove the screws. xx1800003082 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 509 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the cable block from the gearbox. xx1800003084 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 510 Screw: M2.5x6 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.6 Nm xx1800003084 Refitting the axis-2 gearbox Action Note Refit the axis-2 gearbox. xx1800003083 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 511 Apply grease Castrol Molub-Alloy 777-1 NG to the inner surface of the lower arm, where contacts the bearing on the swing support. xx2000000058 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 512 Refitting the axis-2 motor Action Note Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 513 Bend the motor signal cable back towards the swing support. xx1800003027 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 514 Install an M6x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000010 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 515 New belt:180-229 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 516 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 517 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 518: Replacing The Axis-3 Gearbox

    The axis-3 gearbox is located as shown in the figure. xx1800002480 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 519 Castrol Molub. Alloy 777-1 NG Used to lubricate bearings on the swing support and lower arm support. Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 520 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (IRB 1100-4/0.475) /95° (IRB 1100-4/0.58) • Axis 3: -20° (IRB 1100-4/0.475)/ -6° (IRB 1100-4/0.58) • Axis 4: 0°...
  • Page 521 The connector plate cannot be removed completely until the connectors are re- move from the plate, as shown in following step. xx1800003004 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 522 CAUTION The support cannot be removed completely. Make sure the hanging support will not wear or damage xx1800003286 the cable harness. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 523 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003008 Remove the timing belt from its grooves on the motor and gearbox. xx1800003022 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 524 Removing the axis-3 gearbox Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 525 Remove the screws on the labyrinth sealing ring. xx1900001425 Remove the labyrinth sealing ring lightly and evenly. xx1900001417 Remove the screws. xx1800003284 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 526 Refit the axis-3 gearbox. xx1800003285 Secure with screws. Screw: M3x30 12.9 Gleitmo 603+Geomet 500 (12 pcs) Tightening torque: 1.8 Nm xx1800003284 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 527 Apply a little Loctite 243 to the screws and secure Screw: M3x4 (2 pcs) the labyrinth sealing ring with the screws. Tightening torque: 0.8 Nm xx1900001425 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 528 Screw: M5x16 12.9 Steel Black Oxide (5 pcs) Tightening torque: 8 Nm xx1800003088 Route the cable package through the lower arm support. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 529 Install an M4x25 or longer adjustment screw to the motor. Note Do not insert the entire screw to the hole. xx1900000009 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 530 New belt: 113-143 Hz (for reference only) If the timing belt tension does not meet the require- ment, loosen the motor screws and readjust. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 531 Refit the cable bracket. Screw: M2.5x6 12.9 Gleitmo 603+Geomet 500 (2 pcs) Tightening torque: 0.6 Nm xx1800003006 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 532 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 533: Replacing The Axis-4 Gearbox

    The axis-4 gearbox is located as shown in the figure. xx1800002481 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1100 via myABB Business Portal, www.mypo- rtal.abb.com. Spare part Article number...
  • Page 534 If no data is found related to standard calibration, manual calibration is used as default. Required consumables Consumable Article number Note Cable straps Grease 3HAC029132-001 FM 222 Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 535 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: 110° (IRB 1100-4/0.475) /95° (IRB 1100-4/0.58) • Axis 3: -20° (IRB 1100-4/0.475)/ -6° (IRB 1100-4/0.58) • Axis 4: 0°...
  • Page 536 The cover can not be removed completely until the connectors are disconnected, as shown in following steps. xx1800002944 Disconnect the air hoses. xx1800002945 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 537 Removing the wrist covers Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 538 Access the connector FB5 from the process hub and disconnect the connector. xx1800002950 Disconnect the connector. • xx1800002993 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 539 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800002995 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 540 Valid for IRB 1100-4/0.475 Access the cable package locking screw on the axis-4 gearbox from the wrist and then loosen the locking screw. xx1800003031 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 541 Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the housing cover. xx1800003011 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 542 Loosen the screws and move the motor slightly to slacken the timing belt. xx1800003094 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 543 Removing the pulley cover and axis-4 timing belt Action Note DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 544 During replacement, always use the same screws (and washers) that are fitted on the robot at delivery. Contact ABB for more informa- tion. xx1900002191 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 545 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Remove the screws. xx1800003300 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 546 5 Repair 5.8.4 Replacing the axis-4 gearbox Continued Action Note Pull out the gearbox. xx1800003310 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 547 Valid for IRB 1100-4/0.475 xx1800003313 Valid for IRB 1100-4/0.58 xx1800003312 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 548 Refit the the wrist to the housing. xx1800003075 Valid for IRB 1100-4/0.58 Refit the extender unit and wrist to the housing. xx1800003100 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 549 Refit the pulley cover. Screw: M3x8 12.9 Gleitmo 603+Geomet 500 (3 pcs) Tightening torque: 1.2 Nm xx1800003097 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 550 Use the motor fitting tool to fix the timing belt. axis-4 motor fitting tool, included in the special toolkit 3HAC071022- 001. xx1900000044 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 551 603+Geomet 500 (3 pcs) Washer, 3HAC064765-001 (3 pcs) Note Do not tighten the screws yet. xx1800003095 Remove the motor fitting tool. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 552 Fit an M3x25 eye bolt o the screw hole. xx1900000037 Use a handheld tensiometer hooking to the eye bolt. xx1900000038 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 553 Tightening torque: 1.4 Nm xx1800003094 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001 below the housing. Tightening torque: 2 Nm Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 554 Wrap the connectors with the masking tape. gearbox. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1800003017 xx1800003601 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 555 Surfaces to be paralleled are shown in the following figures. xx1800003019 xx1800003020 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 556 Valid for IRB 1100-4/0.58 Plug screw: 3HAC064146-001 Refit the plug screw and washer on the extender Tightening torque: 2 Nm unit. xx1800003000 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 557 Apply grease to the cable package, cover all moving area of the package. Apply grease to the covers that have contacting area with the cable package. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 558 Recalibrate the robot. Calibration is detailed in section Calibration on page 559. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 559: Calibration

    A calibration routine to make a rough calibration of each manipulator axis. Synchronization mark Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 560: Calibration Methods

    Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 1100 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
  • Page 561 References Article numbers for the calibration tools are listed in the section Special tools on page 608. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 562: When To Calibrate

    If the robot is not floor mounted, then the robot accuracy could be affected. The robot needs to be calibrated after it is mounted. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 563: Synchronization Marks And Axis Movement Directions

    Before installing a tool on the tool flange, make sure a visible mark has been made to the tool at the corresponding position. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 564: Calibration Movement Directions For All Axes

    Positive directions are shown in the graphic below. Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below. Manual movement directions xx1800002456 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 565: Updating Revolution Counters

    Use the following procedure to check and correct the axis 4 position. Action Note Remove the housing cover. xx1800003011 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 566 Jog the axis 4 anti-clockwise (with the operator facing the rear) until the cable harness is in vertic- al state. 0° 60° 120° 180° 300° 240° xx1800003318 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 567 At delivery the manipulator is in the correct position. Do NOT rotate axis 4 at power up before the revolution counters are updated. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 568 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 587. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 569: Calibrating With Axis Calibration Method

    Risk of pinching! The contact force for large robots can be up to 150 kg. Keep a safe distance to the robot. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 570 Reference calibration routine Note Axes 5 and 6 of the IRB 1100 cannot be calibrated with reference calibration. Choose this routine to create reference values and to calibrate the robot when the robot is dressed with tools, process cabling or other equipment.
  • Page 571 Special requirement How to calibrate a suspended or wall mounted robot The IRB 1100 is calibrated floor standing in factory, prior to shipping. To calibrate a suspended or wall mounted robot, reference calibration must be used. Reference values for a suspended or a wall mounted robot must be created with the robot mounted at its working position, not standing on a floor.

  • Page 572: Calibration Tools For Axis Calibration

    The tool box also includes a unique calibra- tion pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6. The robot is calibrated by either manual calibration or Axis Calibration at factory. Always use the same calibration method as used at the factory.
  • Page 573 If including the tool flange calibration tool in a local periodic check system, the following measures should be checked. • Outer diameter within Ø5g5 mm. • Straightness within 0.005 mm. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 574 6 Calibration 6.4.2 Calibration tools for Axis Calibration Continued xx1600001142 Outer diameter Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 575: Installation Locations For The Calibration Tools

    For axis 6 there is only one bushing, the second calibration tool is installed at the mounting flange of the turning disk. xx1800003320 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 576 Replace damaged parts with new. Spare part Article number Note Protective plug for bushing 3HAC059556-001 Replace if damaged or missing. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 577 6 Calibration 6.4.3 Installation locations for the calibration tools Continued Spare part Article number Note Calibration pin cover, 6 mm 3HAC061926-001 Replace if damaged or missing. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 578: Axis Calibration - Running The Calibration Procedure

    Required if Axis Calibration is the valid calibration method for the robot. The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6. The robot is calibrated by either manual calibration or Axis Calibration at factory. Always use the same calibration method as used at the factory.
  • Page 579 Before starting the calibration procedure, you must jog each axis and bring the robot to synchronization position and make sure that all the notches are matched. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 580 The axis is calibrated and the system returns to the list of available mechanical units. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 581 FlexPendant is given in Overview of the calibra- tion procedure on the FlexPendant on page 578. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 582 Replace the cover with new spare part, if missing or damaged. xx1900001421 Calibration pin cover, 6 mm: 3HAC061926-001 Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 583 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protective plug for bushing: 3HAC059556-001. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 584: Reference Calibration

    (step 5, see Brief introduction to Reference Calibration on page 584). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 585 10 Check again against the verification position. 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 586: Verifying The Calibration

    Write down the values on a new label and stick it on top of the calibration label. The label is located on one side of the base. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 587: Checking The Synchronization Position

    If they do not, up- ization position for axes on page 563 date the revolution counters. Updating revolution counters on page 565. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 588 This page is intentionally left blank...

  • Page 589: Troubleshooting

    Check: been installed • the configuration files • connectors • options and their configuration • changes in the robot working area/movements. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 590 The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 591: Oil And Grease Stains On Motors And Gearboxes

    "cooling periods" into the your local ABB representative. application. • Overpressure created inside gearbox. Inspect all sealings and gaskets between motor and gearbox. Replace broken parts. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 592: Mechanical Noise Or Dissonance

    Make sure the bearings are fitted correctly. Tighten the screws if a heat sink, fan, or metal sheet is loose. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 593 Investigate whether it chased from your local ABB representat- is possible to program small "cooling ive. periods" into the application. • Overpressure created inside gearbox. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 594: Manipulator Collapses On Power Down

    Remove the motor from the gearbox to in- If found faulty, the motor must be replaced spect it from the drive side. as a complete unit. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 595: Decommissioning

    These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 596: Environmental Information

    Base, base adapter, swing, swing support, lower arm, lower arm support, swing, covers, motors, gearboxes, SMB unit, etc Lead Serial measurement board Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 597 China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of IRB 1100 according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ".

  • Page 598: Scrapping Of Robot

    • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 599: Reference Information

    9.1 Introduction 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 600: Applicable Standards

    Degrees of protection provided by enclosures (IP code) Only robots with protection Clean Room. Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 601 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 602: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 603: Screw Joints

    Any special torque specified overrides the standard torque! • Use the correct tightening torque for each type of screw joint. • Only use correctly calibrated torque keys. Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 604 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 605 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 606: Weight Specifications

    Following is an example of a weight specification in a procedure: Action Note CAUTION The arm weighs 25 kg. All lifting accessories used must be sized accord- ingly. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 607: Standard Toolkit

    Ratchet head for torque wrench 1/2 Hex socket head cap no. 2.5 socket 1/2" bit L=110 mm Small screwdriver T-handle with ball head Small cutting plier Plastic mallet Needle-nose plier Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.

  • Page 608: Special Tools

    Required if Axis Calibration is the valid calibration method for the robot. The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6. Acoustic tensiometer Used for measuring the timing belt tension.

  • Page 609: Spare Parts

    Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 610 This page is intentionally left blank...

  • Page 611: Index

    563 information labels location, 87 CalibWare, 560 inspecting carbon dioxide extinguisher, 27 information labels, 87 cleaning, 85 robot cabling, 90 climbing on robot, 29 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 612 39 inspecting, 90 original spare parts, 15 rubber overfilled gearbox, 591 disposal, 596 pedestal safety installed on pedestal, 26 brake testing, 33 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 613 17 replacing, 51 synchronization position, 565 sync marks, 563 system integrator requirements, 26 zero position system parameter checking, 587 Gravity Alpha, 61 Gravity Beta, 60 Product manual - IRB 1100 3HAC064992-001 Revision: C © Copyright 20192020 ABB. All rights reserved.
  • Page 616 ABB AB, Robotics Robotics and Motion S-721 68 VÄSTERÅS, Sweden Telephone +46 (0) 21 344 400 ABB AS, Robotics Robotics and Motion Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 22 87 2000 ABB Engineering (Shanghai) Ltd. Robotics and Motion No.

This manual is also suitable for:

Irb 1100-4/0.475Irb 1100-4/0.58

Table of Contents