crb_1100

ROBOTICS
Product manual
CRB 1100
Trace back information:
Workspace 24A version a16
Checked in 2024-03-07
Skribenta version 5.5.019
Product manual
CRB 1100-4/0.475
CRB 1100-4/0.58
OmniCore
Document ID: 3HAC078007-001

Revision: M
© Copyright 2021-2024 ABB. All rights reserved.

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

Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 13
How to read the product manual ...................................................................................................... 15
Network security ............................................................................................................................... 16
1 Safety 17
1.1 Safety information ............................................................................................. 17
1.1.1 Limitation of liability ................................................................................. 17
1.1.2 Requirements on personnel ...................................................................... 18
1.2 Safety signals and symbols ................................................................................. 19
1.2.1 Safety signals in the manual ...................................................................... 19
1.2.2 Safety symbols on manipulator labels ......................................................... 21
1.3 Robot stopping functions .................................................................................... 27
1.4 Safety during installation and commissioning ......................................................... 28
1.5 Safety during operation ...................................................................................... 30
1.6 Safety during maintenance and repair ................................................................... 31
1.6.1 Safety during maintenance and repair ......................................................... 31
1.6.2 Emergency release of the robot axes .......................................................... 33
1.6.3 Brake testing .......................................................................................... 34
1.7 Safety during troubleshooting .............................................................................. 35
1.8 Safety during decommissioning ........................................................................... 36
2 Manipulator description 37
2.1 About CRB 1100 ............................................................................................... 37
2.2 Technical data .................................................................................................. 38
2.3 Safety data ....................................................................................................... 42
2.4 Dimensions ...................................................................................................... 43
2.5 Working range ................................................................................................. 45
2.6 The unit is sensitive to ESD ................................................................................. 48
3 Installation and commissioning 49

3.1 Introduction to installation and commissioning ....................................................... 49
3.2 Unpacking ....................................................................................................... 50
3.2.1 Pre-installation procedure ......................................................................... 50
3.2.2 Risk of tipping/stability ............................................................................. 51
3.3 On-site installation ............................................................................................ 54
3.3.1 Lifting the robot ...................................................................................... 54
3.3.1.1 Lifting the robot by one person ....................................................... 54
3.3.1.2 Lifting and rotating a suspended mounted robot ................................ 56
3.3.2 Orienting and securing the robot ............................................................... 57
3.3.3 Manually releasing the brakes ................................................................... 59
3.3.4 Setting the system parameters for an inverted or a tilted robot ......................... 61
3.3.5 Loads fitted to the robot, stopping time and braking distances ......................... 66
3.3.6 Fitting equipment on the robot (robot dimensions) ......................................... 67
3.3.7 Installation of lead-through device .............................................................. 72
3.3.8 Installation of laser scanner ...................................................................... 79
3.4 Restricting the working range .............................................................................. 87
3.4.1 Adjusting the working range ...................................................................... 87
3.4.2 Mechanically restricting the working range ................................................... 88
3.5 Electrical connection .......................................................................................... 89
3.5.1 Robot cabling and connection points .......................................................... 89
3.5.2 Customer connections ............................................................................. 92
3.6 Start of robot in cold environments ...................................................................... 95
3.7 Configuring the software ..................................................................................... 96
3.7.1 Information about RobotWare and CRB 1100 ............................................... 97
3.7.2 Information about Collaborative Speed Control add-in .................................... 98
Product manual - CRB 1100 5

3HAC078007-001 Revision: M
Table of contents
3.7.3 Lead-through .......................................................................................... 100

3.7.4 SafeMove .............................................................................................. 107
3.7.4.1 The SafeMove configurator app on FlexPendant ............................... 107
3.7.4.2 Configuration of SafeMove using Visual SafeMove in RobotStudio ....... 118
3.7.5 Speed control ......................................................................................... 123
3.7.5.1 Configuration of one PROFINET-base laser scanner (RobotWare 7.5 or
earlier) ....................................................................................... 123
3.7.5.2 Configuration of one PROFIsafe-based laser scanner (RobotWare 7.6 or
later and PLC acting as Master) ...................................................... 129
3.7.5.3 Configuration of two PROFIsafe-based laser scanners (RobotWare 7.6 or
later and PLC acting as Master) ...................................................... 133
later and OmniCore acting as Master) .............................................. 137
3.7.5.5 Configuration of two PROFIsafe-based laser scanners (RobotWare 7.10
or later and OmniCore acting as Master) .......................................... 141
3.7.5.6 Configuration of one SafetyIO-base laser scanner (RobotWare 7.6 or
later) ......................................................................................... 145
3.7.5.7 Configuration of two SafetyIO-base laser scanners (RobotWare 7.6 or
later) ......................................................................................... 150
3.7.5.8 Speed control strategies ............................................................... 155
3.7.6 Robot status indication ............................................................................. 158
3.7.7 Use cases of safety configurations ............................................................. 160
3.8 Test run after installation, maintenance, or repair .................................................... 165
4 Maintenance 167
4.1 Introduction ...................................................................................................... 167
4.2 Maintenance schedule and expected component life ............................................... 168
4.2.1 Specification of maintenance intervals ........................................................ 168
4.2.2 Maintenance schedule ............................................................................. 169
4.2.3 Expected component life ......................................................................... 171
4.3 Cleaning activities ............................................................................................. 172
4.3.1 Cleaning the CRB 1100 ............................................................................ 172
4.4 Inspection activities ........................................................................................... 173
4.4.1 Inspecting the information labels ................................................................ 173
4.4.2 Inspecting the robot cabling ..................................................................... 175
4.4.3 Inspecting timing belts ............................................................................ 176
4.5 Lubricating activities .......................................................................................... 180
4.5.1 Lubricating the cable package ................................................................... 180
4.6 Replacing/changing activities .............................................................................. 182
4.6.1 Replacing the battery pack ........................................................................ 182
5 Repair 189
5.1 Introduction ...................................................................................................... 189
5.2 General procedures ........................................................................................... 190
5.2.1 Mounting instructions for sealings .............................................................. 190
5.2.2 Cut the paint or surface on the robot before replacing parts ............................ 194
5.3 Cable harness .................................................................................................. 195
5.3.1 Replacing the upper cable package ........................................................... 196
5.3.2 Replacing the lower cable package ............................................................ 239
5.3.3 Replacing the SMB unit ........................................................................... 273
5.4 Swing and base ................................................................................................ 281
5.4.1 Replacing the base ................................................................................. 281
5.4.2 Replacing the swing ................................................................................ 322
5.5 Lower arm ....................................................................................................... 365
5.5.1 Replacing the lower arm ........................................................................... 365
5.6 Housing, extender unit and wrist .......................................................................... 395
5.6.1 Replacing the housing .............................................................................. 395
5.6.2 Replacing the extender unit and wrist ......................................................... 437
6 Product manual - CRB 1100

Table of contents
5.7 Motors ............................................................................................................ 477

5.7.1 Replacing the axis-1 motor ....................................................................... 477
5.7.2 Replacing the axis-2 motor ........................................................................ 492
5.8 Gearboxes ....................................................................................................... 546
5.8.1 Replacing the axis-1 gearbox .................................................................... 546
6 Calibration 651
6.1 Introduction to calibration ................................................................................... 651
6.1.1 Introduction and calibration terminology ...................................................... 651
6.1.2 Calibration methods ................................................................................. 652
6.1.3 When to calibrate ................................................................................... 654
6.2 Synchronization marks and axis movement directions ............................................. 655
6.2.1 Synchronization marks and synchronization position for axes ......................... 655
6.2.2 Calibration movement directions for all axes ................................................ 656
6.3 Updating revolution counters ............................................................................... 657
6.3.1 Updating revolution counters on OmniCore robots ........................................ 657
6.4 Calibrating with Axis Calibration method ............................................................... 661
6.4.1 Description of Axis Calibration .................................................................. 661
6.4.2 Calibration tools for Axis Calibration ........................................................... 664
6.4.3 Installation locations for the calibration tools ............................................... 666
6.4.4 Axis Calibration - Running the calibration procedure ...................................... 669
6.4.5 Reference calibration ............................................................................... 675
6.5 Calibrating with Wrist Optimization method ........................................................... 677
6.6 Verifying the calibration ...................................................................................... 679
6.7 Checking the synchronization position .................................................................. 680
6.7.1 Checking the synchronization position on OmniCore robots ............................ 681
7 Troubleshooting 683
7.1 Introduction to troubleshooting ............................................................................ 683
7.2 Oil and grease stains on motors and gearboxes ...................................................... 685
7.3 Mechanical noise or dissonance .......................................................................... 686
7.4 Manipulator collapses on power down ................................................................... 687
7.5 Motor temperature too high ................................................................................. 688
7.6 Robot vibration during low speed movement .......................................................... 689
7.7 Communication failure between PROFIsafe-based laser scanner, PLC, and controller .... 691
7.8 Communication failure between PLC and controller ................................................. 692
7.9 Communication failure between scalable I/O device and controller ............................. 694
7.10 Errors related to stopped background task T_SWIFTI_LED ....................................... 695
7.11 Unable to change speed value in FlexPendant ........................................................ 696
7.12 Movement in Safe area not in full speed or at zero speed ......................................... 697
7.13 Unable to remove or reselect installed options in Collaborative Speed Control add-in .... 698
7.14 Unexpected robot movement when starting the program in Protecting Area ................. 699
7.15 Program execution stops because no safety configuration template loaded ................. 700
8 Decommissioning 701
8.1 Introduction to decommissioning ......................................................................... 701
8.2 Environmental information .................................................................................. 702
8.3 Scrapping of robot ............................................................................................. 704
9 Reference information 705

9.1 Introduction ...................................................................................................... 705

Table of contents
9.2 Applicable standards ......................................................................................... 706

9.3 Unit conversion ................................................................................................. 707
9.4 Screw joints .................................................................................................... 708
9.5 Weight specifications ......................................................................................... 711
9.6 Standard toolkit ................................................................................................ 712
9.7 Special tools .................................................................................................... 713
10 Spare parts 715

10.1 Spare part lists and illustrations ........................................................................... 715
Index 717

Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the CRB 1100
• maintenance of the CRB 1100
• mechanical and electrical repair of the CRB 1100
The robot described in this manual has the following protection types:
• Standard
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
It is the responsibility of the integrator to conduct a risk assessment of the final

application.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
Product manual scope

The manual covers all variants and designs of the CRB 1100. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
Continues on next page

Continued
References
Documentation referred to in the manual, is listed in the table below.
Document name Document ID
Product manual, spare parts - CRB 1100 3HAC078009-001
Product specification - CRB 1100 3HAC082108-001
Safety manual for robot - Manipulator and IRC5 or OmniCore con- 3HAC031045-001
troller i
Product manual - OmniCore C30 3HAC060860-001
Operating manual - OmniCore 3HAC065036-001
Application manual - Controller software OmniCore 3HAC066554-001
Application manual - CalibWare Field 3HAC030421-001
Technical reference manual - Event logs for RobotWare 7 3HAC066553-001
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC065041-001
Application manual - PROFINET Controller/Device 3HAC066558-001
Application manual - Functional safety and SafeMove 3HAC066559-001
Operating manual - RobotStudio 3HAC032104-001
Circuit diagram - CRB 1100 3HAC076518-003
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
Revision Description
A First edition.
B Published in release 21B. The following updates are done in this revision:
• Text regarding fastener quality is updated, see Fastener quality
on page 71.
• Text regarding diameter of air hoses is updated, see Customer
connections on page 92.
• Added delivery information about the attachment screws, see At-
tachment screws on page 57.
• Added maintenance activities of running the Brake Check and
Cyclic Brake Check routines. See Maintenance schedule on
page 169.
• Removed maintenance activity of inspecting oil seepage and up-
dated troubleshooting description about oil and grease stains on
motors and gearboxes.
• Added a caution about cleaning the lamp unit cover. See Cleaning
methods on page 172.
• Updated the tightening torque for fitting the lamp unit cover from
0.15 Nm to 0.1 Nm.
• Added a note to remind users that mechanical stop locations
cannot be adjusted. See Adjusting the working range on page 87.

Continued
C Published in release 21C. The following updates are done in this revision:
• Added a note to the procedure of enabling the lead-through device.
• Added spare part parallel pin on extender unit and updated related
refitting procedure of extender unit.
• Corrected the description of connection point on cabinet.
• Updated the naming of timing belt tension adjustment tools, from
acoustic tensiometer and tensiometer to sonic tension meter and
dynamometer, respectively.
D Published in release 22A. The following updates are done in this revision:
• Added information about length of thread engagement for attach-
ment screws.
• Added cautions in procedures of removing timing belts, motors
and gearboxes.
• Updated dimension figures to include dimension for bottom con-
nector interface option.
• Added troubleshooting for high motor temperature, see Motor
temperature too high on page 688.
• Updated information about Gleitmo treated screws, see Screw
joints on page 708.
• Updated information of lead-through device and laser scanner
connection and configuration due to new introduction of Collabor-
ative Speed Control add-in and new laser scanner options. See
Installation of lead-through device on page 72, Installation of laser
scanner on page 79 and Configuring the software on page 96.
• Removed caution about not to use cleaning detergents containing
ethanol, organic solvent or similar to clean the lamp cover.
E Published in release 22B. The following updates are done in this revision
• Updated the optional port from LAN port to MGMT port, which is
used to connect the cable from robot to controller for lead-through
functionality.
• Added installation and configuration of the two-button-type lead-
through device.
• Added a list of general software configuration procedure.
• Added a note about the requirement for connecting lamp unit
cabling.
F Published in release 22C. The following updates are done in this revision
• Updated robot power cable information, see Robot cables on
page 89.
• Updated spare part numbers for axes 1-6 motors.
• Added expected life of gearboxes.
• Updated cable connection figures for safetyIO-based scanner(s).
• Added the lamp unit cabling when the controller is configured with
safety I/O device DSQC1042.
• Added a caution about carefully using of the lead-through device
on the robot.
• Updated information label figure.
• Updated the connection figures and configuration procedure of
the safetyIO-based laser scanners.
• Removed the troubleshooting for issue of RED flashing status on
Scalable I/O device and failure to move the robot.
G Published in release 22D. The following updates are done in this revision:
• Added information about Wrist Optimization in calibration chapter.
• Added notes about installation and configuration of additional
scalable I/O device.

Continued
H Published in release 23A. The following updates are done in this revision:
• Added the direct connection between the laser scanner and Om-
niCore controller.
J Published in release 23B. The following updates are done in this revision:
• Added pin assignment on XG1 connector of SafetyIO-based laser
scanner.
• Updated the logical expressions for SafeMove configuration using
Visual SafeMove, see Configuring pre logic on page 118.
K Published in release 23C. The following updates are done in this revision:
• Updated article number of robot signal cable from 3HAC067446-
00X to 3HAC084767-00X.
• Added connection information about scalable I/O devices, see
Scalable I/O device connection on page 93.
• Updated the Ethernet floor cable list.
L Published in release 23D. The following updates are done in this revision:
• Added axis positions for most stable transport position.
• Added spare parts cable protector, axis 3 (3HAC088722-001) and
cable protector, axis 4 (3HAC088723-001).
• Updated the installation procedure for the Collaborative Speed
Control add-in.
• Added troubleshooting for issue that program execution stops
because no safety configuration template loaded.
M Published in release 24A. The following updates are done in this revision:
• Added troubleshooting about robot vibration.
• Updated information about timing belt inspection and refitting.

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack, and most other hardware is delivered with
a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Troubleshooting.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.

Continued
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.

How to read the product manual
How to read the product manual

Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.

Network security
Network security
Network security
This product is designed to be connected to and to communicate information and
data via a network interface. It is your sole responsibility to provide, and
continuously ensure, a secure connection between the product and to your network
or any other network (as the case may be).
You shall establish and maintain any appropriate measures (such as, but not limited
to, the installation of firewalls, application of authentication measures, encryption
of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB
Ltd and its entities are not liable for damage and/or loss related to such security
breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.

1 Safety
1.1.1 Limitation of liability
1 Safety
1.1 Safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed as
intended.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and
approved for their intended use. The installation and/or use of non-original spare
parts and equipment can negatively affect the safety, function, performance, and
structural properties of the robot. ABB is not liable for damages caused by the use
of non-original spare parts and equipment.

1 Safety
1.1.2 Requirements on personnel
1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Personal protective equipment

Use personal protective equipment, as stated in the instructions.

1 Safety
1.2.1 Safety signals in the manual
1.2 Safety signals and symbols
Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
WARNING Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in serious
injury.
ELECTRICAL Signal word used to indicate a potentially hazardous

SHOCK situation related to electrical hazards which, if not
avoided, could result in serious injury.
CAUTION Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in slight
injury.
ELECTROSTATIC Signal word used to indicate a potentially hazardous

DISCHARGE (ESD) situation which, if not avoided, could result in severe
damage to the product.
NOTE Signal word used to indicate important facts and

conditions.

1 Safety
Continued
Symbol Designation Significance

TIP Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.

1 Safety
1.2.2 Safety symbols on manipulator labels
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 21.
The information labels can contain information in text.
Symbols on safety labels
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839

1 Safety
Continued
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
xx0900000813
Before disassembly, see product manual
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

1 Safety
Continued
Symbol Description
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

1 Safety
Continued
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616

1 Safety
Continued
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Adjustable chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824

1 Safety
Continued
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
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

1 Safety
1.3 Robot stopping functions
1.3 Robot stopping functions
Protective stop and emergency stop

The protective stops and emergency stops are described in the product manual
for the controller.
For more information see:
• Product manual - OmniCore C30

1 Safety
1.4 Safety during installation and commissioning
National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in
accordance with the safety requirements set forth in the applicable national and
regional standards and regulations.
The integrator of the robot system is required to perform a risk assessment.
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Hazards due to noise emission from the robot needs to be considered.
Allergenic material
See Environmental information on page 702 for specification of allergenic materials
in the product, if any.
Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the
respective product manual.
When the robot is installed at a height, hanging, or other than mounted directly on
the floor, there will be additional hazards.
Using lifting accessories and other external equipment

Ensure that all equipment used during installation, service and all handling of the
robot are in correct condition for the intended use.
Electrical safety
Incoming mains must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.

1 Safety
Continued
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.
Verify the safety functions

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.

1 Safety
1.5 Safety during operation
1.5 Safety during operation
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
Unexpected movement of robot arm
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.

1 Safety
1.6.1 Safety during maintenance and repair
1.6 Safety during maintenance and repair
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Make sure that there are no tools, loose screws, turnings, or other unexpected
parts remaining after maintenance or repair work.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
Gearbox lubricants (oil or grease)

When handling oil, grease, or other chemical substances the safety information of
the respective manufacturer must be observed.
Note
Take special care when handling hot lubricants.

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease
When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction

1 Safety
Continued

When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries
are sealed and not exposed to the outside.
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads
to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Operating conditions, robot on page 41.
See safety instructions for the batteries in Material/product safety data
sheet - Battery pack (3HAC043118-001).
Related information
See also the safety information related to installation and operation.

1 Safety
1.6.2 Emergency release of the robot axes
1.6.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 59.

1 Safety
1.6.3 Brake testing
1.6.3 Brake testing
When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each axis to a position where the combined weight of the manipulator
and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
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.
Note
It is recommended to run the service routine BrakeCheck as part of the regular

maintenance, see the operating manual for the robot controller.
For robots with the option SafeMove, the Cyclic Brake Check routine is
recommended. See the manual for SafeMove in References on page 10.

1 Safety
1.7 Safety during troubleshooting
1.7 Safety during troubleshooting
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Troubleshooting on the controller while powered on must be performed by

personnel trained by ABB or by ABB field engineers.
A risk assessment must be done to address both robot and robot system specific
hazards.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.

1 Safety
1.8 Safety during decommissioning
1.8 Safety during decommissioning
General
See section Decommissioning on page 701.
If the robot is decommissioned for storage, take extra precaution to reset safety
devices to delivery status.

2 Manipulator description
2.1 About CRB 1100
2.1 About CRB 1100
Introduction
The CRB 1100 is one of ABB Robotics latest generation of 6-axis robot, with a
payload of 4 kg, designed based on industrial robot platform. It bridges the gap
between industrial robots and robots designed for collaborative applications.
Combing ABB SafeMove solution, safety separation technology and speed control
with safety laser scanner(s) and lead-through programming with a lead-through
device, CRB 1100 enables safe collaborative operations and harmless contacts
between robot and the operator. The robot has an open structure that is especially
adapted for flexible use, and can communicate extensively with external systems.

2.2 Technical data
2.2 Technical data
Weight, robot
The table shows the weight of the robot.
Robot model Nominal weight
CRB 1100 21.1 kg
Note
The weight does not include additional options, tools and other equipment fitted
on the robot.
Mounting positions
The table shows valid mounting positions and the installation (mounting) angle for
the manipulator.
Mounting position Installation angle
Floor mounted Any angle
Wall mounted Any angle
Suspended Any angle
Table mounted Any angle
Note
The actual mounting angle must always be configured in the system parameters,
otherwise the performance and lifetime is affected. See Setting the system
parameters for an inverted or a tilted robot on page 61.
Loads on foundation, robot

The illustration shows the directions of the robots stress forces.

2.2 Technical data
Continued
The directions are valid for all floor mounted, table mounted, wall mounted and
suspended robots.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).
Floor mounted
Force Endurance load (in operation) Maximum load (emergency stop)

Force xy ±420 N ±710N
Force z +210 ±380 N +210 ±510 N
Torque xy ±180 Nm ±330 Nm
Torque z ±90 Nm ±140 Nm

2.2 Technical data
Continued
Wall mounted
Force Endurance load (in operation) Max. load (emergency stop)

Force xy +210 ±370 N +210 ±660 N
Force z ±370 N ±540 Nm
Torque xy ±200 Nm ±370Nm
Suspended
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±420 N ±710 N
Force z -210 ±380 N -210 ±510 N
Table mounted
Force Endurance load (in operation) Maximum load (emergency stop)

Force xy ±420 N ±710N
Force z +210 ±380 N +210 ±510 N
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.1/500 mm Flat foundations give better repeatability of
surface the resolver calibration compared to original
settings on delivery from ABB.
The value for levelness aims at the circum-
stance of the anchoring points in the robot
base.
In order to compensate for an uneven sur-
face, the robot can be recalibrated during in-
stallation. If resolver/encoder calibration is
changed this will influence the absolute ac-
curacy.
Minimum resonance 22 Hz The value is recommended for optimal per-
frequency formance.
Note Due to foundation stiffness, consider robot
mass including equipment. i
It may affect the ma- For information about compensating for
nipulator lifetime to foundation flexibility, see the description of
have a lower reson- Motion Process Mode in the manual that de-
ance frequency than scribes the controller software option, see
recommended. References on page 10.

2.2 Technical data
Continued
Requirement Value Note

Minimum foundation 150 MPa
material yield strength
i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated frequency. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.
Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter Value
Minimum ambient temperature -25°C (-13°F)
Maximum ambient temperature +55°C (+131°F)
Maximum ambient temperature (less than 24 hrs) +70°C (+158°F)
Maximum ambient humidity 95% at constant temperature
(gaseous only)
Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature +5°C i (41°F)
Maximum ambient temperature +45°C (113°F)
Maximum ambient humidity 95% at constant temperature
i At low environmental temperature (below 10° C) a warm-up phase is recommended to be run with
the robot. Otherwise there is a risk that the robot stops or runs with lower performance due to
temperature dependent oil and grease viscosity.
Protection classes, robot

The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type Protection class i
Manipulator, protection type Standard IP40
i According to IEC 60529.
Environmental information
The product complies with IEC 63000. Technical documentation for the assessment
of electrical and electronic products with respect to the restriction of hazardous
substances.

2.3 Safety data
2.3 Safety data
Prevailing standards and directives

For the use of industrial robots, regulations must be fulfilled as described in the
following standards and directives:
• EN ISO 10218-1:2011
Risk assessment
The results of a risk assessment performed on the robot and its intended application
may determine that a safety-related control system performance other than that
stated in ISO 10218 is warranted for the application.
Safety functions and safety related data

Safety functions and safety related data for CRB 1100 rely on the controller and
safety laser scanners.
Safety data for the controller is detailed in the product manual of the robot controller,
see References on page 10.
Safety data for the safety laser scanners is detailed in the user manual from the
vendor, see Operating instructions microScan3 - PROFINET and Operating
instructions microScan3 - Pro I/O that are available on SICK® website.

2.4 Dimensions
2.4 Dimensions
Main dimensions of CRB 1100-4/0.475
314
A C
250 64
10
225
609
562
327
173
135 17
182
101
158
135
57 57
78 64
158
173
xx2000002545
Pos Description
A Turning radius: R85
B Turning radius: R109
C Turning radius: R61

2.4 Dimensions
Continued
Main dimensions of CRB 1100-4/0.58

364
C
A 300 64
10
280
664
617
327
17
135
101
182
158
135
57 57
78 64
158
173
xx2000002546
Pos Description

2.5 Working range
2.5 Working range
Illustration, working range CRB 1100-4/0.475

This illustration shows the unrestricted working range of the robot.
Pos 1
802.2
Z
Pos 0
488.6
Pos 9 453.4
Pos 6
Pos 7 Pos 3
Pos 5 327
Pos 2
Pos 4 141.3
Pos 8
126.2
0
X
0
475
475
87.6
430.7
248.2
153.8
188.4
437.4
xx2000002543
Positions at wrist center and angle of axes 2 and 3
Position in the Positions at wrist center (mm) Angle (degrees)

figure
X Z axis 2 axis 3
pos0 314 562 0° 0°
pos1 0 802 0° -87.7°
pos2 53.8 327 9.7° 55°
pos3 475 327 90° -87.7°
pos4 437.4 141.3 113° -87.7°
pos5 -248.2 327 -26.4° -205°
pos6 -87.6 453.4 -115° 55°
pos7 -475 327 -90° -87.7°
pos8 -430.7 126.2 -115° -87.7°
pos9 188.4 488.6 113° -205°

2.5 Working range
Continued
Illustration, working range CRB 1100-4/0.58

This illustration shows the unrestricted working range of the robot.
Pos 1
907.2
Z
Pos 0
617
Pos 9 517.1
473.5
Pos 6
Pos 7
327
Pos 5 Pos 2 Pos 3
Pos 8 Pos 4 100.3

81.8
0
X
82.6
91.5
0
580
304
534
580
525.8
112.4
184.6
237.3
xx2000002544
Positions at wrist center and angle of axes 2 and 3
Position in the Positions at wrist center (mm) Angle (degrees)

figure
X Z axis 2 axis 3
pos0 364 617 0° 0°
pos1 0 907.2 0° -88°
pos2 184.6 327 12.5° 55°
pos3 580 327 90° -88°
pos4 534 100.3 113° -88°
pos5 -304 327 -28.3° -205°
pos6 -112.4 473.5 -115° 55°
pos7 -580 327 -90° -88°
pos8 -525.8 81.8 -115° -88°
pos9 237.3 517.1 113° -205°

2.5 Working range
Continued
Top view of working range

° R475 (CRB 1100-4/0.475)
30
+2
R580 (CRB 1100-4/0.58)
R109 (A)
Y
R53.8 (CRB 1100-4/0.475)
-23
0° R184.6 (CRB 1100-4/0.58)
xx2100002541
Working range
Axis Working range Note

Axis 1 ±230° Wall mounted robot has a work area for axis 1
that depends on payload and the positions of
other axes. Simulation in RobotStudio is recom-
mended.
Axis 2 -115°/+113°
Axis 3 -205°/+55°
Axis 4 ±230°
Axis 5 -125°/+120°
Axis 6 ±400° Default value.
±242 Maximum revolution value.
The default working range for axis 6 can be exten-
ded by changing parameter values in the soft-
ware.

2.6 The unit is sensitive to ESD
2.6 The unit is sensitive to ESD
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Use one of the following alternatives:
• Use a wrist strap.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.

3 Installation and commissioning
3.1 Introduction to installation and commissioning

3.1 Introduction to installation and commissioning
General
This chapter contains assembly instructions and information for installing the CRB
1100 at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
The technical data is detailed in section Technical data on page 38.
Safety information
Before any installation work is commenced, all safety information must be observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 17 before performing any installation
work.
Note
Always connect the CRB 1100 and the robot to protective earth and residual
current device (RCD) before connecting to power and starting any installation
work.

3.2.1 Pre-installation procedure
3.2 Unpacking
3.2.1 Pre-installation procedure
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Prerequisites for installation personnel

Installation personnel working with an ABB product must:
• Be trained by ABB and have the required knowledge of mechanical and
electrical installation/maintenance/repair work.
• Conform to all national and local codes.
Checking the pre-requisites for installation
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Stop unpacking and contact ABB if transport damages are found.
4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 38
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 41
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 41
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 38
• Protection classes, robot on page 41
• Requirements, foundation on page 40
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 51
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 54
11 Install required equipment, if any.
• Installation of lead-through device on page 72
• Installation of laser scanner on page 79

3.2.2 Risk of tipping/stability
Risk of tipping
If the robot is not fastened to the foundation while moving the arm, the robot is not
stable in the whole working area. Moving the arm will displace the center of gravity,
which may cause the robot to tip over.
The transportation position is the most stable position.
Do not change the robot position before securing it to the foundation!
Transportation position
This figure shows the robot in its transportation position.
CRB 1100-4/0.475
45°
35°
10°
xx2100000153

Continued
CRB 1100-4/0.58
45°
35°
10°
xx2100000154
Note
The robot might be positioned in a different position at delivery, due to actual

configurations and options (for example DressPack).
Axis number Angle of axis

Axis 1 0°
Axis 2 -10°
Axis 3 +55°
Axis 4 0°
Axis 5 45°
Axis 6 0°

Continued
WARNING
The robot is likely to be mechanically unstable if not secured to the foundation.

3.3.1.1 Lifting the robot by one person
3.3 On-site installation
3.3.1 Lifting the robot
General
This section describes how to lift the robot and move it by one person.
Grasping location
Position Grasping location Note

Stand on foot When the robot stands on its foot, grasp
the robot with one hand holding the lower
arm and the other hand holding the swing.
xx2100000155
By side When the robot lies by side, grasp the ro-

bot with one hand holding the lower arm
and the other hand supporting at the base.
It is recommended to hold the robot
between your arm and body.
xx2100000156
Invented When the robot is inverted, grasp the robot

with one hand supporting at the housing
and the other hand holding the base.
xx2100000157

Continued
Lifting and transporting the robot
Action
1
CAUTION
The CRB 1100 weighs,

21.1 kg
and can be lifted by one person.
2 Grasp the robot as instructed in Grasping location on page 54.

3 Lift the robot.
4 Move the robot to desired position.
CAUTION
Be careful so that the robot does not bump into something while lifting and
transporting. It could damage the robot.
5 Secure the robot on a workbench according to section Orienting and securing the
robot on page 57.

3.3.1.2 Lifting and rotating a suspended mounted robot
3.3.1.2 Lifting and rotating a suspended mounted robot
Introduction
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.

3.3.2 Orienting and securing the robot
General
This section describes how to orient and secure the robot to the base plate or
foundation in order to run the robot safely.
Attachment screws
The table below specifies the type of securing screws and washers to be used for
securing the robot to the base plate/foundation.
All hardware is enclosed in the robot delivery.
Suitable screws M12x25 (robot installation directly on foundation)
Quantity 4 pcs
Quality 8.8
Suitable washer 4 pcs, 24 x 13 x 2.5
Guide pins 2 pcs, article number 3HNP00449-1
Tightening torque 50 Nm±5 Nm
Length of thread engagement Minimum 12.5 mm for ground with material yield strength
150 MPa
Level surface requirements 0.1/500 mm i
i See Requirements, foundation on page 40.
Securing a floor mounted robot

Use this procedure to orient and secure the robot floor mounted.
Action Note
1 Make sure the installation site for the robot con-
forms to the specifications in section Technical
data on page 38.
2 Prepare the installation site with attachment holes. The hole configuration of the base
The foundation surface must be clean and un- is shown in the figure in Hole con-
painted. figuration, base on page 58.
3
CAUTION
The weight of the CRB 1100 robot is 21.1 kg

All lifting accessories used must be sized accord-
ingly.
4
CAUTION
When the robot is put down after being lifted or

transported, there is a risk of it tipping, if not
properly secured.
5 Lift the robot. See Lifting the robot on page 54.

6 Fit two pins to the holes in the base. 2 pcs, article number 3HNP00449-
1

Continued
Action Note
7 Guide the robot gently, using the attachment Make sure the robot base is cor-
screws while lowering it into its mounting position. rectly fitted onto the pins.
8 Fit the securing screws and washers in the attach- Screws: M12x25 (robot installation
ment holes of the base. directly on foundation), 4 pcs,
quality 8.8
Washers: 4 pcs, 24 x 13 x 2.5
9 Tighten the bolts in a crosswise pattern to ensure Tightening torque: 50 Nm±5 Nm
that the base is not distorted.
Hole configuration, base

This illustration shows the hole configuration used when securing the robot.
6
135
11
11.5
5.5
4
10
135
10
11
R16
A-A A A
11.5
+0.012
4x M12 10 6 H7 0
4
5.5
11
135
5.5
11
11.5 +0.012
4x R16
135 6 H7 0
xx1800002448

3.3.3 Manually releasing the brakes
Introduction to manually releasing the brakes

This section describes how to release the holding brakes for the axes motors.
Location of the brake release unit

The brake release unit is located as shown in the figure.
xx2100000158
Releasing the brakes

This procedure describes how to release the holding brakes when the robot is
equipped with a brake release unit.
Action Note
1
Note
If the robot is not connected to the controller, power

must be supplied to the connector R1.MP according
to the section Supplying power to connector R1.MP
on page 60.
2
DANGER
When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unexpec-
ted ways.
Make sure no personnel is near or beneath the ro-
bot.

Continued
Action Note
3 Release the holding brake of all axes by pressing
the brake release button.
The brake will be enable as soon as the button is
released.
WARNING
Pressing the brake release button will release the

holding brakes on all axes simultaneously.
xx2100000158
Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector
R1.MP on the robot, in order to enable the brake release buttons.
Action Note
1
DANGER
Incorrect connections, such as supplying power

to the wrong pin, may cause all brakes to be
released simultaneously and instantly!
2 Supply
• 0V on pin 12.
• 24V on pin 11.
Note
Do not interchange the 24V and 0V pins.

If they are mixed up, damage can be caused to
internal electrical components.
xx1800002443
3 Use the brake releasing button as described in

Releasing the brakes on page 59.

3.3.4 Setting the system parameters for an inverted or a tilted robot
General
The robot is configured for mounting parallel to the floor, without tilting, on delivery.
If the robot is mounted in any other angle than 0°, then the system parameters
that describe the mounting angle (how the robot is oriented relative to the gravity)
must be re-defined.
Note
With inverted installation, make sure that the gantry or corresponding structure
is rigid enough to prevent unacceptable vibrations and deflections, so that
optimum performance can be achieved.
Note
The mounting positions are described in Mounting positions on page 38, and
the requirements on the foundation are described in Requirements, foundation
on page 40.
System parameters
Note
The mounting angle must be configured correctly in the system parameters so

that the robot system can control the movements in the best possible way. An
incorrect definition of the mounting angle will result in:
• Overloading the mechanical structure.
• Lower path performance and path accuracy.
• Some functions will not work properly, for example Load Identification and
Collision detection.
Gravity Beta
When the robot is mounted other than floor-standing (rotated around the y-axis),
the robot base frame and the system parameter Gravity Beta must be redefined.
If the robot is mounted upside down (inverted), then Gravity Beta should be π
(+3.141593).
If the robot is mounted on a wall, then Gravity Beta should be ±π/2 (±1.570796).
The Gravity Beta is a positive rotation direction around the y-axis in the base
coordinate system. The value is set in radians.
Gravity Alpha
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).

Continued
The Gravity Alpha is a positive rotation direction around the x-axis in the base
coordinate system. The value is set in radians.
Note
The system parameter Gravity Alpha is not supported for all robot types.
If the robot does not support Gravity Alpha, then use Gravity Beta along with the
re-calibration of axis 1 to define the rotation of the robot around the x-axis.
Note
The parameter is supported for all robots on track when the system parameter
7 axes high performance motion is set, see Technical reference manual - System
parameters.
Gamma Rotation
Gamma Rotation defines the orientation of the robot foot on the travel carriage
(track motion).
Mounting angles and values

The parameter Gravity Beta (or Gravity Alpha) specifies the mounting angle of the
robot in radians. It is calculated in the following way.
Gravity Beta = A° x 3.141593/180 = B radians, where A is the mounting
angle in degrees and B is the mounting angle in radians.
Example of position Mounting angle (A°) Gravity Beta

Floor mounted 0° 0.000000 (Default)
Wall mounted 90° 1.570796
Inverted mounting 180° 3.141593

Continued
Examples of mounting angles tilted around the Y axis (Gravity Beta)
xx1800002454
Pos 1 Floor mounted

Pos 2 Mounting angle 45° (Tilted)
Pos 3 Mounting angle 90° (Wall)
Pos 4 Mounting angle 180° (Suspended)

Continued
Examples of mounting angles tilted around the X axis (Gravity Alpha)

The following illustration shows the IRB 120, but the same principle applies for all
robots.
0°
xx2100000297
xx2100000299 xx2100000300
Mounting angle Gravity Alpha

0° (Floor mounted) 0
90° (Wall) 1.570796
-90° (Wall) -1.570796
Note
For suspended robots (180°), it is recommended to use Gravity Beta instead of

Gravity Alpha.
Limitations in working area

If mounting the robot on a wall, the working range of axis 1 is limited. These
limitations are specified in the table Working range on page 47.
Defining the system parameters in RobotWare

The value of the system parameters that define the mounting angle must be
redefined when changing the mounting angle of the robot. The parameters belong
to the type Robot, in the topic Motion.

Continued
The system parameters are described in Technical reference manual - System

parameters.
The system parameters are configured in RobotStudio or on the FlexPendant.

3.3.5 Loads fitted to the robot, stopping time and braking distances
3.3.5 Loads fitted to the robot, stopping time and braking distances
Define loads carefully

Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. 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.
See the product specification for the robot, listed in References on page 10.

3.3.6 Fitting equipment on the robot (robot dimensions)
Robot dimensions
Dimensions CRB 1100-4/0.475
The figure shows the dimension of the CRB 1100-4/0.475.
314
A C
250 64
10
225
609
562
327
173
135 17
182
101
158
135
57 57
78 64
158
173
xx2000002545
Pos Description

Continued
Dimensions CRB 1100-4/0.58

The figure shows the dimension of the CRB 1100-4/0.58.
364
C
A 300 64
10
280
664
617
327
17
135
101
182
158
135
57 57
78 64
158
173
xx2000002546
Pos Description
Attachment holes and dimensions

Extra loads can be mounted on robot. Definitions of dimensions and masses are
shown in the following figures. The robot is supplied with holes for fitting extra
equipment.

Continued
Maximum allowed arm load depends on center of gravity of arm load and robot
payload.
Holes for fitting extra equipment
B
B
(4x) M3 x6
145
16
B
(4x) M4x6
A
D
40
C
(4x) M5x10
169
40
D
xx1800002449
Pos CRB 1100-4/0.475 CRB 1100-4/0.58

A 248 303
B 200 250

Continued
17
(2x) M4 6
40
E
G
(4x) M3 6
14
F
426
(2x) M4 8
24
G
xx1800002450

Continued
Tool flange standard
+0.021
J
0
+0.012
5 H7 0 6
20 H7
4.5
0.04
6
(4x) 90°
57.3
4x M5 6
0.25
45°
0.6
31.5
J-J
J
xx1800002451
CAUTION
To calibrate the axis 6, the notch on the wrist must be aligned with the marked
pin hole on the tool flange. Before installing a tool on the tool flange, make sure
a visible mark has been made to the tool at the corresponding position.
For details about the synchronization mark, see Synchronization marks and
synchronization position for axes on page 655.
Fastener quality
When fitting tools on the tool flange, only use screws with quality 12.9. For other
equipment use suitable screws and tightening torque for your application.

3.3.7 Installation of lead-through device
Introduction
The lead-through functionality is available for the CRB 1100 by mounting a
lead-through device on axis 6. With the lead-though functionality enabled, you can
hold the handler of the lead-through device and move the robot arm manually to
the desired position, as an alternative to jogging.
To use lead-through, make sure the system is running in manual mode; otherwise,
the functionality cannot be enabled. If running the system in auto mode, always
remove the lead-through device from the robot first to prevent any unexpected
damages.
CAUTION
Be careful not to stretch or squeeze the device cabling when moving the robot
with the lead-through device, especially to extreme positions. Otherwise, it will
cause cabling damages.
Note
Two types are available to the lead-through device used with the CRB 1100,
no-button-type and two-button-type. The actual delivered device type varies
according to the order time. Unless otherwise stated, the instructions of installing
and configuring the device are applicable to both no-button-type device and
two-button-type device. Always read the instructions carefully to install and
configure your device based on the actual device type.

Continued
Location of lead-through device

The lead-though device is located as shown in the figure.
xx2100000159
A Adapter
B Lead-through device base
Note: base for no-button-type lead-through device is shown as an example.
C Lead-through device
Note: no-button-type lead-through device is shown as an example.
Preparing the adapter

The lead-through device is mounted to the device base and then to the robot tool
flange through an adapter. Customers can use an L-shape adapter offered by ABB
(option 3314-1) or design adapters according to actual requirements. During adapter
design, hole dimensions on the device base and robot tool flange shall be
considered.

Continued
The following figure illustrates the hole dimensions on lead-through device base.
For no-button type

44
38,7
6,6 THRU ALL
4 x M4 - 6H THRU ALL 25,5 R16,75 18,9 10 7
3,3 THRU ALL A19,5 R4,25 12,8 11 X 90°, Near Side
13,4 3,2 10 R1 6,3
4 x M4 - 6H THRU ALL
3,3 THRU ALL
4x 7,3 6
8,7
4x 9 THRU ALL
17
9,6
18,2
19,5
19,5
9,1
65
2x 6,2 THRU ALL
24
2x 7.94 THRU ALL
3/8-16 UNC THRU ALL
R27
R3,2
R3,2
10,5 1 3,1 10,5

A SECTION A-A 19,5
xx2100000164
For two-button type

19,5 ±0,15 R3
R29,75
26,4
19,5 ±0,15
39,4
4 x M4 THRU
2x 4.5 THRU
8 4.4
16,9
25 ±0,1
36
8
10,1
20
30°
52 68,8
xx2200000767
For the hole dimensions on robot tool flange, see Tool flange standard on page 71.
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 CRB 1100 via myABB Business Portal,
www.abb.com/myABB.
Spare part Article number Note

Lead-through device 3HAC075974-001

Continued

Lead-through device base (for no- 3HAC075975-001
button type)
Lead-through device with buttons 3HAC082590-001
Lead-through device base (for two- 3HAC082591-001
button type)
Cabling M8-M12, 500 mm (for lead- 3HAC077018-001
through device)
Ethernet cable M12- RJ45, 7m (for 3HAC077020-001
lead-through device)
Installing the lead-through device

Use the following procedure to install the lead-through device.
Note
The lead-through device can be installed in any position according to actual

applications. Figures in the following procedures only illustrate an example
position.
Preparations before installing the lead-through device
Action Note
1 Remove all tools from the mounting flange.
2 Jog the robot to the synchronization position. Calibration is detailed in section
Calibration on page 651.
3 Prepare the lead-through device adapter. Refer to Preparing the adapter on
page 73.
CAUTION
To calibrate the axis 6, the notch on the wrist must

be aligned with the marked pin hole on the tool
flange. Before installing the adapter on the tool
flange, make sure a visible mark has been made
to the adapter at the corresponding position.
For details about the synchronization mark, see
Synchronization marks and synchronization posi-
tion for axes on page 655.

Continued
Action Note
4 Install the adapter to mounting flange. Following figures illustrate installa-
tion of the offered L-shape adapter
Note (option 3314-1).
Specification and tightening torque
Secure the adapter to the tool flange using the of screws fixing the adapter to the
screw holes circled in the following figure if there tool flange vary according to actual
are no other tools to be fitted. Otherwise, the tools applications.
should use these holes as via holes to be fitted
to the robot.
xx2100000281
Screw: M3x8 12.9 Lafre

2C2B/FC6.9 (4 pcs)
xx2100000167 Tightening torque: 1.8 Nm
xx2000002222
Installing the lead-through device (no-button type)
Action Note
1 Install the device base to the adaptor. Screw: M4x16 12.9 Lafre
2C2B/FC6.9 (4 pcs)
Tightening torque: 3 Nm
xx2000002223

Continued
Action Note
2 Insert the lead-through device to the base.
xx2000002224
3 Turn the adjusting knob to lock the lead-through

device.
Note
Do not use excessive force!

The arrow in the figure indicates the direction of
locking the lead-through device.
xx2000002225
Installing the lead-through device (two-button type)
Action Note
1 Install the device base to the adaptor. Screw: M4x16 12.9 Lafre
2C2B/FC6.9 (4 pcs)
xx2200000763
2 Insert the lead-through device to the base.
xx2200000764

Continued
Action Note
3 Turn the adjusting knob to lock the lead-through
device.
Note
Do not use excessive force!

The arrow in the figure indicates the direction of
locking the lead-through device.
xx2200000765
Connecting the cables
Action Note
1 Connect the cabling between the lead-through
device and robot.
• R2.C2 connector on process hub of robot
(A)
• Lead through device connector (B)
xx2200000766
2 Connect the cable between robot and controller. A B C

• R1.C2 connector on robot base (A)
• Ethernet switch port on controller (B)
• X19 connector on controller (C)
Note
Ethernet switch port is available for use only when

the 5 Port Ethernet switch option is selected.
Otherwise, connect the cable to the MGMT port.
Note
Pins 3 and 4 of X19 connector are used for the

lead-through device connection while pins 1 and
2 are occupied by the CP/CS cable for lamp unit.
xx2100000292
Configuring the lead-through functionality

The lead-through functionality is predefined for robots that are delivered with the
option 3313-1 Lead-through Device ordered.
If the lead-through option is newly ordered for an existing robot and the robot
system is operating in RobotWare 7.6 or later, the Collaborative Speed Control
add-in must be installed to the system to activate the lead-through functionality.
For details about how to install the add-in and configure the lead-through
functionality, see Lead-through on page 100.

3.3.8 Installation of laser scanner
Overview
The safety separation technology and speed control for CRB 1100 is based on the
connection and communication of one or two safety laser scanners in the robot.
Laser scanner(s) provides a timely and continuous monitor on the activities within
its scanning area and forms a protective field. One laser scanner can provide a
scanning range of approximately 275°. The system integrator shall investigate the
site environment and place the laser scanner to a suitable location according to
the actual requirements.
CAUTION
Safety in the area that not in the scanning range must always be considered.
The system integrator shall assess the potential risks within this area and make
sure that proper measures have been applied to reduce risks.
275°
xx2100000168
Laser scanner types

The following laser scanner package options are available:
• 1 PROFIsafe-based laser scanner (option 3051-1 PROFIsafe scanner)
• 2 PROFIsafe-based laser scanners (option 3051-3 Dual PROFIsafe scanner)
• 1 SafetyIO-based laser scanner (option 3051-2 I/O scanner)
• 2 SafetyIO-based laser scanners (option 3051-4 Dual I/O scanner)

Continued
Connection between PROFIsafe-based laser scanners and the OmniCore controller

differs according to the PROFINET options selected and installed in the system.
• If only options [3020-2] PROFINET Device and [3023-2] PROFIsafe Device
are selected and installed, the laser scanners shall connect to a PLC acting
as a master first and then to the OmniCore controller with SafeMove via the
PROFINET safe (PROFIsafe) network. Users need to prepare a safety PLC
of their own.
• If options [3020-1] PROFINET Controller and [3023-1] PROFIsafe Controller
are selected and installed, the laser scanner could communicate with the
OmniCore controller directly via the WAN port.
SafetyIO-based laser scanners connects to the OmniCore controller with SafeMove
and installed with the scalable I/O device DSQC1042 Safety digital base (option
3037-2). For details about the scalable I/O device, see the product specification of
the controller and Application manual - Scalable I/O.
The supported PROFINET- and SafetyIO-base laser scanners are SICK® microScan
3 Core and SICK® microScan 3 Pro, respectively. Detailed scanner model can be
obtained on the scanner nameplate. Other scanner types or models might not
provide full functionality.
For more details about the safety laser scanners, see Operating instructions
microScan3 - PROFINET and Operating instructions microScan3 - Pro I/O from
the vendor, which are available on SICK® website.
Connecting the laser scanner(s)

Safety laser scanners shall be connected properly according to the scanner type
and system setup.
Note
External 24V power supply shall be prepared for power connection of laser
scanners.
1 PROFIsafe-based laser scanner (option 3051-1), with PLC connected
OmniCore controller PLC Laser Scanner
WAN XF1 XD1
white blue
black
brown
24V + 0V
PROFIsafe PROFIsafe
xx2100000160

Continued
1 PROFIsafe-based laser scanner (option 3051-1), without PLC connected
OmniCore controller Laser Scanner
WAN XF1 XD1
white blue
black
brown
24V + 0V
PROFIsafe
xx2300000226
2 PROFIsafe-based laser scanners (option 3051-3), with PLC connected
OmniCore controller PLC Laser Scanner1

WAN XF1 XD1
white blue
black
brown
PROFIsafe PROFIsafe
24V+ 0V
Laser Scanner2
XF1 XD1
white blue
black
brown
PROFIsafe
24V+ 0V
xx2200000298

Continued
2 PROFIsafe-based laser scanners (option 3051-3), without PLC connected
OmniCore controller Laser Scanner1

WAN XF1 XD1
Router
white blue
black
brown
PROFIsafe PROFIsafe
24V+ 0V
Laser Scanner2
XF1 XD1
white blue
black
brown
PROFIsafe
24V+ 0V
xx2300000227
1 SafetyIO-based laser scanner (option 3051-2)
Power
DSQC 1042
X1 X19
X2
Laser Scanner
XG1 XD1
OmniCore
controller white blue
black
brown
24V+ 0V
xx2200000299

Continued
2 SafetyIO-based laser scanners (option 3051-4)
Power
DSQC 1042
X1 X19
X2
Laser Scanner
XG1 XD1
OmniCore
controller white blue
black
brown
24V+ 0V
Laser Scanner 2
XG1 XD1
white blue
black
brown
24V+ 0V
xx2200000300
Note
If there are additional scalable I/O devices available, install and configure the
additional devices by following the detailed procedures in Application
manual - Scalable I/O.

Continued
Connector information
Pin assignment on XG1 of SafetyIO-based laser scanners
XG1 connector on SafetyIO-based laser scanner is a 17-pin, A-coded M12 female
connector. Pins 1-4 and pin 17 on XG1 are occupied for connecting the laser
scanner and scalable I/O device, while other 12 pins can be used for local inputs
and outputs.
xx2300000750
Pin Description Wiring color

1 OSSD pair 1, OSSD A Brown
2 OSSD pair 1, OSSD B Blue
3 OSSD pair 2, OSSD A White
4 OSSD pair 2, OSSD B Green
5 Universal input 1 Pink
6 Universal input 2 Yellow
7 Universal input 3 Black
8 Universal input 4 Grey
9 Universal input 5 Red
10 Universal input 6 Violet
11 Universal input 7 Grey with pink
12 Universal input 8 Red with blue
13 Universal input 9 White with green
14 Universal input 10 Brown with green
15 Universal output 1 White with yellow
16 Universal output 2 Yellow with brown
17 Voltage 0 V DC White with grey

Continued
Configuring the laser scanner(s)

Laser scanner configuration depends on the type and number of scanners
connecting to the robot and RobotWare version. Refer to the following table for
applicable scenario and proceed to specific section for configuration details.
Scanner type Works with... RobotWare ver- Re- Refer to...
sion quire...
Number of connected
Collaborative Speed Con-

OmniCore controller with
deviceDSQC1042
scanners
Scalable I/O
trol add-in
SafeMove
PLC
PROFIsafe-based Y N Y 1 RobotWare 7.5 or N Configuration of one PROFINET-

earlier base laser scanner (RobotWare 7.5
or earlier) on page 123
Y N Y 1 RobotWare 7.6 or Y Configuration of one PROFIsafe-
later based laser scanner (RobotWare
7.6 or later and PLC acting as
Master) on page 129
Y N Y 2 RobotWare 7.6 or Y Configuration of two PROFIsafe-
later based laser scanners (RobotWare
7.6 or later and PLC acting as
Master) on page 133
N N Y 1 RobotWare 7.10 or Y Configuration of one PROFIsafe-
later based laser scanner (RobotWare
7.10 or later and OmniCore acting
as Master) on page 137
N N Y 2 RobotWare 7.10 or Y Configuration of two PROFIsafe-
later based laser scanners (RobotWare
7.10 or later and OmniCore acting
as Master) on page 141
SafetyIO-based N Y Y 1 RobotWare 7.6 or Y Configuration of one SafetyIO-base
later laser scanner (RobotWare 7.6 or
later) on page 145
N Y Y 2 RobotWare 7.6 or Y Configuration of two SafetyIO-base
later laser scanners (RobotWare 7.6 or
later) on page 150

Continued
The following table lists the required actions for specific scenarios such as
RobotWare upgrade or rollback.
Scenario Actions
RobotWare 7.5 or an earlier ver-
sion upgraded to RobotWare 7.6 Note
or a later version
Applicable only when using PROFIsafe-based laser scanners
1 Install the Collaborative Speed Control add-in. See Information about
Collaborative Speed Control add-in on page 98.
2 Reconfigure the PLC and laser scanner. See Configuration of one
PROFIsafe-based laser scanner (RobotWare 7.6 or later and PLC acting
as Master) on page 129.
RobotWare 7.6 or a later version
rolled back to RobotWare 7.5 or an Note
earlier version
Reconfigure the PLC and laser scanner. See Configuration of one PROFINET-
base laser scanner (RobotWare 7.5 or earlier) on page 123.
Adding a new laser scanner 1 Connect the new laser scanner in the same type as the one existing in
the system. See Connecting the laser scanner(s) on page 80.
2 Configure the new laser scanner. See Configuration of two PROFIsafe-
based laser scanners (RobotWare 7.6 or later and PLC acting as Master)
on page 133 or Configuration of two SafetyIO-base laser scanners (Robot-
Ware 7.6 or later) on page 150.
Connection via a PLC changed to
direct connection with the Omni- Note
Core Controller
1 Upgrade the robot system to RobotWare 7.10 or later, and install the op-
tions [3020-1] PROFINET Controller and [3023-1] PROFIsafe Controller
to the system.
2 Reconfigure the laser scanners. See Configuration of one PROFIsafe-
based laser scanner (RobotWare 7.10 or later and OmniCore acting as
Master) on page 137 or Configuration of two PROFIsafe-based laser
scanners (RobotWare 7.10 or later and OmniCore acting as Master) on
page 141.

3.4.1 Adjusting the working range
3.4 Restricting the working range
3.4.1 Adjusting the working range
Reasons for adjusting the manipulator working range

The working range of each manipulator axis is configured in the software. If there
is a risk that the manipulator may collide with other objects at installation site, its
working space should be limited. The manipulator must always be able to move
freely within its entire working space.
Working range configurations

The parameter values for the axes working range can be altered within the allowed
working range and according to available options for the robot, either to limit or to
extend a default working range. Allowed working ranges and available options for
each manipulator axis are specified in Working range on page 47.
Mechanical stops on the manipulator

Mechanical stops are and can be installed on the manipulator as limiting devices
to ensure that the manipulator axis does not exceed the working range values set
in the software parameters.
Note
The mechanical stops are only installed as safety precaution to physically stop
the robot from exceeding the working range set. A collision with a mechanical
stop always requires actions for repair and troubleshooting.
Axis Fixed mechanical stop i Movable mechanical stop ii

Axis 1 yes no
Axis 2 yes no
Axis 3 yes no
Axis 4 no no
Axis 5 yes no
Axis 6 no no
i Part of the casting or fixed on the casting and can not /should not be removed.
ii Can be installed in one or more than one position, to ensure a reduced working range, or be removed
to allow extended working range.

3.4.2 Mechanically restricting the working range
3.4.2 Mechanically restricting the working range
Location of the mechanical stops

Only axis 1 has a replacable mechanical stop.
xx1800002452
Note
www.abb.com/myABB.

Mechanical stop, axis 1 3HAC061947-001 Replace if damaged.
Replacement of the axis-1 mechanical stop

The axis-1 mechanical stop is accessible after removing the base, see Replacing
the base on page 281.

3.5.1 Robot cabling and connection points
3.5 Electrical connection
Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
DANGER
Turn off the main power before connecting any cables.
CAUTION
Verify that the serial number is according to the number(s) in the Declaration of
Incorporation (DoI).
Main cable categories

The following table specifies cabling categories between the robot and the
controller. Some of the cabling belong to optional applications.
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the serial measurement board.
Specified in the table Robot cables on page 89.
Customer cables Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
The customer cables also handle databus communication.
The customer cables also include the air hose.
See the product manual for the controller, see document
number in References on page 10.
Air hoses The hose for compressed air is integrated with the manipu-
lator cable harness.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cables, power Transfers drive power from the X1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers resolver data from X2 R1.SMB
and power supply to the serial
measurement board.

Continued
Robot cable, power
Power cable length Article number

Power cable, straight connector, 3 m 3HAC077245-001
Power cable, angled connector, 3 m 3HAC077247-001
Robot cable, signals
Signal cable length Article number

Signal cable, shielded: 3 m 3HAC084767-001
Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.
A
B
xx1600002016
A Diameter
B Diameter x10

Continued
Grounding and bonding point on manipulator

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
Customer cables - CP/CS cable
CP/CS cable length i Article number

3 m, with lamp unit cabling 3HAC078069-001
i CP/CS cable for CRB 1100 also includes lamp unit cabling used for communication with the lamp
unit on the process hub. The cable is also designed with free ends for more I/O connections and
shall always be used properly in applications. It is recommended to shield the free ends not in use.
Do not use other types of CP/CS cables or use in an improper way; otherwise, the lamp unit will
not work and other unknown faulty may be raised.
Customer cables - Ethernet floor cable
Ethernet floor cable length Article number

7m 3HAC067447-002
15 m 3HAC067447-003
7 m, with lead-through device cabling i 3HAC077020-001
i Ethernet floor cable with lead-through device cabling is used for communication with the lead-through
device when installed. Another Ethernet cable of 500 mm is used between the lead-through device
and R2.C2 connector on robot wrist.

3.5.2 Customer connections
Introduction to customer connections

The cables for customer connection are integrated in the robot and the connectors
are placed on the wrist and one at the base. There is one connector R2.C1 at the
wrist. Corresponding connector R1.C1 is located at the base.
There is also connections for Ethernet, one connector R2.C2 at the wrist and the
corresponding connector R1.C2 located at the base.
Hose for compressed air is also integrated into the manipulator. There are 4 inlets
at the base (R1/8”) and 4 outlets (M5) on the wrist.
(A) (B)
(C) (C)
(A)
(B)
(C)
xx1900000131
Position Connection Description Number Value

A (R1)R2.C1 Customer power/signal 4 wires i 30 V, 1.5 A
B (R1)R2.C2 Customer power/signal 8 wires ii 30 V, 1 A or 1 Gbits/s
or Ethernet
C Air Max. 6 bar 4 Outer diameter of air hose:
4 mm
i The connector has 12 pins. Only pins 5 to 8 are available for use. Pins 1 to 4 are used for LED
indicator, and pins 9 to 12 are not connected internally.

Continued
ii If the lead-through device is installed, the C2 connector will be used for the lead-through device
and 6 wires are occupied.
Connector kits (optional)

Connector kits, wrist
The table describes the CP/CS and Ethernet (if any) connector kits for wrist.
Position Description Art. no.
Connector kits CP/CS M12 CPCS Male straight connect- 3HAC066098-001
or kits
M12 CPCS Male angled connector 3HAC066099-001
kits
Ethernet M12 Ethernet Cat5e Male straight 3HAC067413-001
connector kits
M12 Ethernet Cat5e Male angled 3HAC067414-001
connector kits
Protection covers
Protection covers for water and dust proofing
Protection covers are delivered together with the robot and must be well fitted to
the connectors in any application requiring water and dust proofing.
Always remember to refit the protection covers after removing them.
(A)
(B)
(C) (C)
xx1900000132
A CP/CS or Ethernet connector protection covers

B SMB connector protection cover
C Air hose connector protection covers
Scalable I/O device connection

For robot working with safetyIO-based laser scanners, a safety I/O device
DSQC1042 will be available and required to be connected with the base I/O device
DSQC1030 installed on the controller.

Continued
The following figure illustrates the connection among manipulator, controller with
base I/O device configured and the safety I/O device.
X3 2
DSQC 1042
1
5
X3
DSQC 1030
Controller
xx2200001154
1 Ethernet connection Between X3 connectors on DSQC1030 and on

DSQC1042
2 Lamp unit cabling Using CP/CS cable to connect,
• X1 connector on DSQC1030
• X19 connector on controller
• R1.C1 connector on manipulator base
3 Power connection Between X4 connector on DSQC1030 and X19
connector on controller
For details about the I/O module models, see Application manual - Scalable I/O.

3.6 Start of robot in cold environments
3.6 Start of robot in cold environments
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
Problems with starting the robot

Event message from Motion Supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up. More information about Motion Supervision is found in Technical
reference manual - System parameters.
Action Note
1 Turn off Motion Supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the Motion Supervision can be turned on
again.
Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.
Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.
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.

3.7 Configuring the software
3.7 Configuring the software
Overview
This section is intended for guiding users to set up robot system and configure
necessary software for CRB 1100. It also contains information of some customizable
safety configurations.
A general software configuration procedure is listed as below.
Action Reference to...
1 Configure RobotWare as required. • Information about Robot-
Ware and CRB 1100 on
page 97
• Operating manual - Integrat-
or's guide OmniCore
2 For robots operating in RobotWare 7.6 or later Information about Collaborative
Download the Collaborative Speed Control add- Speed Control add-in on page 98
in and install required options.
3 Configure the lead-through functions. Lead-through on page 100
4 Configure SafeMove.
For PROFIsafe-based scenarios with a PLC • The SafeMove configurator
acting as the master connected (any supported app on FlexPendant on
RobotWare version) page 107
For SafetyIO-based scenarios • Application manual - Func-
tional safety and SafeMove
Upload the template SafeMove configuration file
using the SafeMove configurator app on FlexPend-
ant.
For PROFIsafe-based scenarios with the control- • Configuration of SafeMove
ler acting as the master (RobotWare 7.10 or using Visual SafeMove in
later) RobotStudio on page 118
Configure the template SafeMove configuration • Application manual - Func-
file using Visual SafeMove in RobotStudio and tional safety and SafeMove
upload to the controller.
5 Configure laser scanner(s) and apply speed con- Speed control on page 123
trol strategies.
6 Get knowledge of the robot status indications Robot status indication on page 158
shown by the lamp unit.
7 If required, modify customizable safety configura- Use cases of safety configurations
tions. on page 160

3.7.1 Information about RobotWare and CRB 1100
3.7.1 Information about RobotWare and CRB 1100
Overview
CRB 1100 is designed to simplify collaborative applications. Therefore some
software features work somewhat different compared with standard industrial
robots. Some of them are listed in this section.
How to configure RobotWare is described in Operating manual - Integrator's guide
OmniCore.
SafeMove
See Application manual - Functional safety and SafeMove.

3.7.2 Information about Collaborative Speed Control add-in
Overview
Note
The Collaborative Speed Control add-in is required only for robots operating in
RobotWare 7.6 or later.
The Collaborative Speed Control add-in is integrated in the robot system at delivery
if option 3313-1 Lead-through device or any of laser scanner options 3351-X are
ordered. It is also available separately in the add-ins section in RobotStudio. To
add it to an existing controller or do an update, see the installation procedure to
install and add it to the robot.
With the Collaborative Speed Control add-in installed, the configuration of the lamp
indicator, lead-through, and speed control are activated for the robot.
For PROFIsafe-based scenarios where a PLC is connected to act as a master and
SafetyIO-based scenarios, after the add-in is installed, a predefined template
SafeMove configuration file is also available for easy configuration of basic
SafeMove functions.
Installing the Collaborative Speed Control add-in

Perform the following procedure to install the Collaborative Speed Control add-in:
1 Start RobotStudio and click Gallery in the Add-Ins ribbon.
2 In the displayed Gallery window, use the Search function or Common tags
to find the Collaborative Speed Control add-in.
3 Click the displayed add-in icon.
4 In the right pane, click Add.
The package is automatically installed and listed in the Add-in navigation
tree in the left pane of the window.
5 Select Add Controller > Connect to Controller in the Controller ribbon.
6 In the Connect to Controller window, connect to a real controller or
select/create a virtual controller and tap OK.
7 Request write access.
8 Launch the Modify Installation dialog from the Controller ribbon.
9 Select Software > Available.
The Available Software window displays all distribution packages that have
been installed with RobotStudio.
Select the Collaborative Speed Control add-in package and required version
to be added to the system and click Include.
10 Proceed to the Features tab page and modify the system as required.

Continued
11 Choose required option in the Collaborative Features group.
Note
If a real controller is connected, the Collaborative Features options are

available only when corresponding license for Lead-through device or
Safety laser scanner is added.
12 The Summary tab shows an overview of all the changes.

13 Select Apply to confirm and save the changes.
The controller is restarted automatically to apply the changes.
See more details about how to use Modify Installation for RobotWare 7 and how
to install a distribution package, see Operating manual - RobotStudio.

3.7.3 Lead-through
3.7.3 Lead-through
What is lead-through?
The lead-through functionality is available for robots designed for collaborative
applications. Using lead-through, you can move the robot manually to a desired
position, as an alternative to jogging.
Using lead-through
Note
For robots newly ordered with option 3313-1 Lead-through Device and operating
in RobotWare 7.6 or later, install the Collaborative Speed Control add-in with the
option [3313-1] Lead-through Device selected first. See Installing the Collaborative
Speed Control add-in on page 98.
Checking lead-through status

The lead-through device is not configured by default. Users can perform the
following procedure to check the configuration status:
1 In the FlexPandant, on the status bar, tap the QuickSet button.
The QuickSet window is displayed.
2 Tap Lead-through.
The Lead-through Settings tab page is displayed.
3 Check the lead-through device setting.
The device is not configured by default and the Enable Lead-through switch
is unavailable for use.

3.7.3 Lead-through
Continued
Note
For robots operating in RobotWare version earlier than 7.7, check the lead-through
status in the Jog Setting tab page by tapping Jog in the QuickSet window.
xx2100000170
Configuring installation information of the lead-through device

Use the following procedure to configure the installation information of the
lead-through device and get it ready for use:
1 Tap Settings on the home page of the FlexPendant.
2 Tap Lead-through Device.
3 For robots installing with the Collaborative Speed Control add-in in version
1.1 or later, choose the lead-through device type from the drop-down list.
Tip
You can click About the versions and refer to the pictures to figure out
your device type.
4 In the Installation page of the displayed window, select the installation

position of the lead-through device.

3.7.3 Lead-through
Continued
Four installation configurations are predefined, Up, Right, Down and Left.
Observe your device and refer to the following table to make sure the actual
device installation position is consistent with the selected configuration.
Device type Observe...
No-button type • The ABB logo on the device is in the correct direction.
• The indicator on the lead-through is in the correct relative
position with the lamp unit on the process hub.
The following figure takes the configuration Up as an example.
xx2100000173
The device details are as follows.
xx2200000597

3.7.3 Lead-through
Continued
Device type Observe...

Two-button type The indicator and locking knob on the lead-through are in the
correct relative position with the lamp unit on the process hub.
The following figure takes the configuration Up as an example.
xx2200000577
The device details are as follows.
xx2200000598
5 If users want to define customized installation position, tap Advanced

installation.
6 In the displayed window, set corresponding parameters according to actual
requirements.
• For robots operating in RobotWare version earlier than 7.7, the device
offset and orientation are available to set.
• For robots operating in RobotWare version 7.7 or later, the device
offset, orientation, tool load mass and mass center are available to set.
7 Tap Apply.
Enabling lead-through
Use the following procedure to enable lead-through:
1 Make sure the robot is in Manual mode.

3.7.3 Lead-through
Continued
2 Enable lead-through in one of the following ways:

• Press the thumb button on the FlexPendant.
xx2100000331
• On the start screen, tap Jog and select the Lead-through menu.
• In the QuickSet menu, select the Lead-through tab.
Note
If the robot is in motors off state, set the controller to Motors On state first
by pressing the three-position enabling device or changing the state in the
Control Panel tab page.
Note
For robots operating in RobotWare version earlier than 7.7, the lead-through
device can only be enabled from the Jog Setting tab page by tapping Jog
in the QuickSet window.
3 In the Lead-through Mode section select a mode.

4 If required, in the Lead-through lock section use the lock button next to a
axis to lock it.
5 Hold the handler of the lead-through device and gently move the robot to the
desired position.
The robot moves to the selected position. If the Lead-through lock option is
selected, the robot moves in such a way that the movement is restricted in
the locked direction.
Note
You can feel if an axis reaches its end position. Do not try to force the axis
beyond this position.
6 If desired, save the position.

3.7.3 Lead-through
Continued
Note
The speed at which the robot moves when using the Lead-through functionality
is managed using the horizontal scroll bar available in the Lead-through Speed
section.
Setting force threshold

In actual applications, some strong background noises, for example, EMC and
radiation, may be treated as a force by the lead-through device, which may results
in an unexpected movement of the robot. To reduce such affections, users are
allowed to set a force threshold. All the forces that are lower than the threshold
will be filtered out.
Use the following procedure to set the force threshold:
3 Tap Force threshold on the left pane.
4 In the displayed window, drag the Force slider to define a response force to
move the robot.
The default force threshold is 10%.
xx2100000176
5 Observe the forces applied on the lead-through device in real time in the
Force monitor area.

3.7.3 Lead-through
Continued
Configuring button functions
Note
The procedure is valid only for two-button type lead-through device.

The button-type lead-through device provides two buttons, flat and raised, for users
to configure specific functions according to application requirements. The button
function configuration is only available to robots:
• operating in RobotWare version 7.6.1 or later, and,
• installing with the Collaborative Speed Control add-in in version 1.1 or later
Use the following procedure to configure the button functions:
3 Tap Configurable buttons on the left pane.
4 Select desired function from the drop-down list for the required button.
• Add a move location: a Move block will be added to Wizard app. This
is the default configuration for the flat button.
• Linear / Reorient: the lead-through mode will be changed between
linear and reorient. This is the default configuration for the raised button.
• Lock Z: the movement along the Z direction will be locked.
• Lock XY: the movement along the X and Y directions will be locked.
After selection, configured action takes effect when pressing the button.

3.7.4.1 The SafeMove configurator app on FlexPendant
3.7.4 SafeMove
Introduction
The application SafeMove on the FlexPendant offers an intuitive way to visualize
and configure a safety configuration for systems with the option SafeMove
Collaborative. This includes stop functions and Cyclic Brake Check. To get started,
see Use cases on page 110.
Tip
Use the online user guide tool, included in the SafeMove configurator app, for
help with the SafeMove configuration setup process.
Note
The SafeMove configurator app is available for the following robots:

• CRB 1100
• CRB 1300
• CRB 15000
The configuration follows the same principles as when using Visual SafeMove in
RobotStudio but the functionality is not as extensive.
Overview of the user interface

The user interface consists of a configurator and a 3D model that visualizes the
robot with the configured encapsulations and zones. The first time that the app is
opened, a default factory setting is loaded. If a safety configuration is loaded, this
will be shown.
• The tab Robot Encapsulation contains the configuration of the encapsulations
of the robot itself.
• The tab Tool Encapsulation contains the configuration of the encapsulations
of the tools.
• The tab Tool Data contains the configuration for the tools.
• The tab Safe Zones contains the configuration of the safe zones.
• The tab Global Settings contains the configuration for Cyclic Brake Check
and supervision settings.
• The tab Synchronization contains functions for software synchronization.
• The Context menu (...) contains functionality for loading, saving, and viewing
configurations, and to reset the configuration.
The functionality is described in detail in Application manual - Functional safety
and SafeMove.

Continued
Prerequisites
• The option SafeMove Collaborative is required.
• To edit a configuration, the grant Safety Services is required. A user without
this grant can view a configuration, but not modify, write it to the controller,
or apply it to the controller.
Template configurations
The template configuration is adapted for the specific manipulator, and typically
contains one or two encapsulations of the arm, one encapsulation of the wrist
(intended for the tool), one or two safe zones, and a Cyclic Brake Check setting.
This configuration is typically a good start for a generic application with a smaller
tool.
The factory setting is an empty safety configuration. A loaded configuration can
be removed and the system is then reset to the factory setting.
Encapsulations
The encapsulations are geometries that can be in the shape of a sphere, capsule,
or lozenge. A sphere or capsule encapsulation can be modified in dimension,
length, and position. A lozenge capsule can also be modified in rotation.
xx2200000445
Note
For the CRB 1100 and CRB 1300, the SafeMove configurator app offers the same
functionality. The screenshots used in the manual can therefore show either one
of the robots.

Continued
Safe zones
The default safe zone is a rectangular box with four vertices. The vertices defines
the shape of the safe zone, and the position in space. More vertices can be added
to define the safe zone. The minimum number of vertices is 4, and the maximum
is 24.
Each vertex can be edited in x and y values.
xx2200000446
Each vertex is numbered, from 1 and up. When a new vertex is added between
two existing vertices the vertex numbers will be automatically adjusted so that they
come in order. For example, if a new vertex is added between vertices 2 and 3, the
vertex with index 3 will change to 4 and the new vertex will be indexed 3.
Display of safety violations

During the validation of a robot cell using the SafeMove app, it is possible to check
whether the robot is committing a safety violation. For example, robot crossing a
forbidden zone, robot speed or force exceeding a certain value, and so on. Once
a violation is detected and displayed on the SafeMove app, it is possible to take
the necessary actions.
For more information about the Display of safety violations, see Application
manual - Functional safety and SafeMove.
Supervision functions
The global supervision functions are not connected to a specific safe zone or safe
range. They can be added, modified, and deactivated.
For more information about the global supervision functions, see Application

Continued
Synchronization
The Synchronization tab is used to manually set the current joint positions for the
robot.
For more information about synchronization, see Application manual - Functional
safety and SafeMove.
Recommended working procedure

Use this procedure when configuring SafeMove in the configurator app on
FlexPendant.
1 Log in as a user with safety user grants.
2 Start the SafeMove configurator app.
3 Load a safety configuration template or an existing configuration from the
Context menu (...).
4 Configure encapsulations.
5 Configure zones and the supervision functions.
6 Load the configuration to the safety controller.
The robot controller is automatically restarted in this step.
7 Validate the configuration.
8 Set the safety configuration to validated and lock it.
For more details, see Use cases on page 110.
For functionality not supported in the SafeMove configurator app, use Visual
SafeMove in RobotStudio.
Use cases
Start the SafeMove configurator app
The SafeMove configurator app is available on the home screen of the FlexPendant
for systems with the option SafeMove Collaborative. If the app is not shown, then
review the system settings using the Modify Installation function in RobotStudio
and add that option.
The first time that the app is opened, a default factory setting is loaded. This
contains only the manipulator with Cyclic Brake Check activated. There are no
encapsulations, safe zones, or tool data defined.
The factory setting can always be resumed, if needed.
To continue and create a safety configuration, see Load a safety configuration
template on page 110.
Load a safety configuration template

The safety configuration template feature is available from RW 7.12 onwards.
Systems with RW 7.10 or earlier will still have the default template solution.
Use the following procedure to load a predefined safety configuration template
and apply it to the robot controller.
2 Open the SafeMove app.
3 Tap Enable Edit Mode.
Continued
The SafeMove Configurator: Select Template page is displayed with a list

of available templates.
xx2300001391
4 Select a template from the list.

The metadata of the selected template is displayed on the right side panel.
5 Tap Load.
The Load Safety Configuration dialogue is displayed.
6 Tap Yes.
The selected safety configuration template is loaded on the FlexPendant.
7 Review that the selected template configuration is suitable for the intended
application.
If modifications are needed, see Modify a loaded safety configuration on
page 112.
Note
A SafeMove configuration must always be validated to verify that the desired

safety is achieved. If no validation is performed, or the validation is
inadequate, the configuration cannot be relied on for personal safety.
8 If the template configuration is suitable, select Write to controller.

The safety report is presented on the screen.
9 Save the safety report. Take a print out and sign this safety report.
See ABB Safety Configuration Report on page 116. More information about
the safety report and how to validate is described in Application
10 Tap Apply to controller.
The Saved dialogue is displayed
Continued
11 Tap Restart Controller.

The controller is restarted and loads the newly saved safety configuration
template.
Note
To change the loaded safety configuration template, tap the Context menu, select
Open Template Selector, select the required template from the list, and follow
the rest of the steps.
Modify a loaded safety configuration

Use the following procedure to modify a loaded safety configuration and apply it
to the robot controller.
The SafeMove Configurator page is displayed along with the saved safety
configuration.
3 Select Enable Edit Mode to edit the loaded safety configuration.
4 To add or modify an encapsulation, tap Add and select a geometry for Robot
Encapsulation or Tool Encapsulation.
To modify the encapsulation, select it and modify the attributes.
5 To add or modify a zone, tap Add and Add Zone.
Select the safe zone and modify the attributes. See Modify a safe zone on
page 113.
6 To add or modify a global setting, tap Add and select which supervision to
modify.
7 When the configuration is done, select Write to controller.
The safety report is presented on the screen.
Note

safety is achieved. If no validation is performed, or the validation is
inadequate, the configuration cannot be relied on for personal safety.
8 Save the safety report. Take a print out and sign this safety report.
The safety report and how to validate is described in detail in Application
9 Tap Apply to controller.
The Saved dialogue is displayed
10 Tap Restart Controller.
The controller is restarted and loads the newly saved safety configuration.

Continued
Modify a safe zone

Use the following procedure to modify a safe zone.
1 Add a new safe zone or select an existing safe zone.
2 Tap Safe Zones to open the attributes.
3 Add, modify, or remove vertices as needed to create the desired shape of
the safe zone.
The green dot in the 3D visualization shows where the new vertex is located.
Use the arrows to change the position (index).
Tap the grey Add button to place the vertex.
xx2200000448
4 To add a supervision to a safe zone, tap to select the safe zone in the 3D
view, then tap Add.
5 Select a supervision function or guide.
xx2200000449

Continued
6 For supervision functions, select stop category, signal, and any other available
setting applicable for the function.
Tip
The functionality is described in detail in Application manual - Functional safety

and SafeMove.
Modify the Standstill Supervision settings

The Standstill Supervision functionality is not active by default. It can be added,
modified, and deactivated.
The CRB 1100 has support for both category 0 stop and category 1 stop.
xx2200000450
Modify the global supervision settings

The global supervision functions are not connected to a specific safe zone or safe
range. They can be added, modified, and deactivated.

Continued
Modify the Cyclic Brake Check settings

The Cyclic Brake Check functionality is active by default. It can be modified and
deactivated.
xx2200000451
Viewing the configuration report

The configuration report is available both on the FlexPendant and on the controller.
It can be viewed from the Context menu.
Loading and exporting a safety configuration

An existing safety configuration on the FlexPendant can be exported from the
Context menu, Save Configuration To File. It is also possible to load a safety
configuration from a file.
Validate the safety configuration
DANGER

safety is achieved. If no validation is performed, or the validation is inadequate,
the configuration cannot be relied on for personal safety.
Each new or modified safety configuration must be validated before running in
production. The validation should verify that the following is configured correctly:
• All I/O settings and signals used for safety interlocking including connected
functionality
• All Stop configuration functions
• All safety zones with connected supervision functions and signals used for
safety interlocking
• All global supervision functions
• All tools with corresponding supervision functions

Continued
Note
Depending on the combination of functions, the validation procedures have to

be modified for the specific configuration.
A more detailed description of validation of the safety configuration is found in
Application manual - Functional safety and SafeMove.
After safety configuration is validated, it must be set to validated and locked in the
system.
Preparations before validation

Do the following checks before you start the validation procedure:
1 Carry out the synchronization procedure.
2 If configured, run the service routine for the function Cyclic Break Check.
3 Turn off the SafeMove Assistant functionality, with the system parameter
Disable SafeMove Assistant.
4 Turn off collision detection during validation of any tool force supervision
5 Start the validation procedure.
If using protected groups in the safety configuration, only the modified parts
must be validated.
ABB Safety Configuration Report

The validation of each function should be documented in the safety report by
signature of the validator.
The safety configuration report lists all parameters that are set for the installation.
The report also includes a visual representation of the installation, a floor plan.
This shows the robot and safety zones as seen from above.
The configuration report includes the checksum (multiple checksums if using
protected groups in the safety configuration). The checksum can also be read
using the RAPID function SafetyControllerGetChecksum or
SafetyControllerGetGroupChecksum.
Setting the configuration to validated

When the safety technician has validated the configuration and signed the safety
report, the status of the configuration shall be changed to Validated on the
FlexPendant.
1 Log in as a user with the grant Safety Services.
2 In the Settings app, select the Safety Controller, and then Configuration.
3 Select the checkbox Validated.
Setting the configuration to locked

When the responsible safety user has approved the validation of the configuration,
the status of the configuration should be changed to Locked on the FlexPendant.

Continued
Running the robot in auto mode with the configuration unlocked will result in a
warning message.
1 Log in as a user with the grant Lock Safety Controller Configuration.
2 In the Settings app, select the Safety Controller, and then Configuration.
3 Select the checkbox Locked.
Concluding steps
After the validation is concluded, turn on the the SafeMove Assistant functionality,
with the system parameter Disable SafeMove Assistant.

3.7.4.2 Configuration of SafeMove using Visual SafeMove in RobotStudio
General
This section describes SafeMove configuration using Visual SafeMove for scenarios
with PROFIsafe-based laser scanners connected and OmniCore controller acting
as master.
What is Visual SafeMove

Visual SafeMove is the configuration tool for SafeMove and the functional safety
options. The tool is completely integrated into the RobotStudio user interface and
takes full advantage of the user interface elements such as tabs, browsers, and
3D graphics.
Visual SafeMove is enabled for robots with the safety module. It offers an intuitive
way to visualize and configure safety zones. Zones can be adjusted by direct
manipulation in the 3D window. Users with previous experience from SafeMove
will recognize the same terminology used as before.
Visual SafeMove is used to configure safety stops. For this purpose, the SafeMove
options are not required, that is, this functionality is available for all robots. More
information about the configuration is available in the product manual for the robot
controller.
Visual SafeMove works both with the real controller and the virtual controller. For
a virtual controller, a RobotStudio station should be used, which allows zones to
be generated automatically. When not running a RobotStudio station, Online
Monitor is used to visualize the robot.
Starting Visual SafeMove
Action
1 Start RobotStudio with a virtual controller (with or without a station) or connect a real
controller.
• The user account logging in the controller must be granted with the Safety
Services permission.
• The write access to the controller is also requested
2 In the Controller tab, click Online Monitor.
(Not needed when running a RobotStudio station.)
3 In the Controller tab, click Safety, then select Visual SafeMove.
Configuring SafeMove
Configuring pre logic
1 On the Visual SafeMove tab page, click Safe IO Configurator in the
Configuration group.
2 Click Pre Logic view in the Safe IO Configuration page.
3 Click New expression and create the following expressions.
• ISH_Activate_SST
• ISH_Activate_TSP
• ISH_Delay_SST

Continued
• ISH_Delay_TSP
• ISH_EnableDelay_Protecting
• ISH_EnableDelay_Warning
• ISH_Combination_Protecting
• ISH_Combination_Waning
In which, the expressions ISH_Combination_Protecting and
ISH_Combination_Waning are required only when two PROFIsafe-based
laser scanners are connected.
4 At the bottom of the Safe IO Configuration page, type the corresponding
logical expression in the text box for each expression and click Create
signals.
Expression Logic
ISH_Activate_SST Valid for scenarios with 1 PROFIsafe-based laser
scanner connected
ISH_Supervise_SST := ((NOT EDGE((NOT Protect-
ingArea1),ISH_Delayed_SST)) OR (NOT ISH_Ena-
bler_Delay_SST))
Valid for scenarios with 2 PROFIsafe-based laser
scanners connected
ISH_Supervise_SST := ((NOT EDGE((NOT Protect-
ingAreaSM),ISH_Delayed_SST)) OR (NOT ISH_Ena-
bler_Delay_SST))
ISH_Activate_TSP Valid for scenarios with 1 PROFIsafe-based laser
scanner connected
ISH_Supervise_TSP := ((NOT EDGE((NOT
WarningArea1),ISH_Delayed_TSP)) OR (NOT ISH_Ena-
bler_Delay_TSP))
scanners connected
ISH_Supervise_TSP := ((NOT EDGE((NOT
WarningAreaSM),ISH_Delayed_TSP)) OR (NOT
ISH_Enabler_Delay_TSP))
ISH_Delay_SST Valid for scenarios with 1 PROFIsafe-based laser
scanner connected
DELAY(ISH_Enabler_Delay_SST,Protect-
ingArea1,(ISH_AtUser_Period_ms_Until_SST /
ISH_SMctrl_Frequency),ISH_Count-
Delay_SST,ISH_Delayed_SST)
scanners connected
DELAY(ISH_Enabler_Delay_SST,Protect-
ingAreaSM,(ISH_AtUser_Period_ms_Until_SST /
ISH_SMctrl_Frequency),ISH_Count-
Delay_SST,ISH_Delayed_SST)

Continued
Expression Logic
ISH_Delay_TSP Valid for scenarios with 1 PROFIsafe-based laser
scanner connected
DELAY(ISH_Ena-
bler_Delay_TSP,WarningArea1,(ISH_AtUser_Peri-
od_ms_Until_TSP / ISH_SMctrl_Frequency),ISH_Count-
Delay_TSP,ISH_Delayed_TSP)
scanners connected
DELAY(ISH_Ena-
bler_Delay_TSP,WarningAreaSM,(ISH_AtUser_Peri-
od_ms_Until_TSP / ISH_SMctrl_Frequency),ISH_Count-
Delay_TSP,ISH_Delayed_TSP)
ISH_EnableDelay_Protect- ISH_Enabler_Delay_SST := (NOT ISH_User-
ing i MODE_bNot_IntermitCollab)
ISH_EnableDelay_Warning ISH_Enabler_Delay_TSP := ((NOT ISH_User-
i MODE_bNot_Cooperation) OR (NOT ISH_User-
MODE_bNot_IntermitCollab))
ISH_Combination_Protect- ProtectingAreaSM := (ProtectingArea1 AND Protect-
ing ii ingArea2)
ISH_Combination_Waning WarningAreaSM := (WarningArea1 AND WarningArea2)
ii
i Required no matter one or two PROFIsafe-based laser scanners are connected.

ii Required only when two PROFIsafe-based laser scanners are connected.
5 Click Signals view in the Safe IO Configuration page and then click Global
signals to expand the signal list.
6 Click on the Create new signal row and create the following signals.
• ISH_TFO_Active
• ISH_TSP_Active
• ISH_TSP_Viol
• ISH_SST_Active
• ISH_SST_Viol
7 Change the default value of following signals.
Signal Default value
ISH_AtUser_Period_ms_Until_SST 650
ISH_AtUser_Period_ms_Until_TSP 550
ISH_SMctrl_Frequency 4
ISH_UserMODE_bNot_Cooperation 1
Creating encapsulation
1 In the Visual SafeMove browser on the left pane of the window, select the
robot (ROB_1) and click Capsule in the Visual SafeMove ribbon tab.
2 Set capsule properties for the robot.
Parameter Value
Radius (mm) 150
Length (mm) 650

Continued
Parameter Value
Start (Flange coordinates) (mm) X value 0
Y value 0
Z value 0
End (Flange coordinates) (mm) X value 650
Y value 0
Z value 0
3 In the Visual SafeMove browser, select the tool and click Capsule in the
Visual SafeMove ribbon tab.
4 Set capsule properties for the tool.
Parameter Value
Radius (mm) 150
Length (mm) 300
Start (Flange coordinates) (mm) X value 0
Y value 0
Z value 0
End (Flange coordinates) (mm) X value 0
Y value 300
Z value 300
Configuring Cyclic Brake Check

1 In the Visual SafeMove ribbon tab, click Cyclic Brake Check.
2 Select the Warning only, no stop check box, enable CBC for all the joints,
and set other cyclic brake check properties.
Parameter Value
Max CRC test interval (h) 48
Pre warning time (h) 6
Standstill tolerance 2
Supervision threshold 0.02
Configuring the supervision functions

1 In the Visual SafeMove ribbon tab, choose Create Safe Zone from the Safe
Zone list.
2 Set zone properties.
Parameter Value
Tool Speed Supervision Pri- BASE
ority
Reference Task frame
Botton, Top (mm) Bottom value 0.000
Top value 2100.000

Continued
Parameter Value
Vertices X, Y (mm) X and Y values for vertices 1 -1400, -1400
X and Y values for vertices 2 1400, -1400
X and Y values for vertices 3 1400, 1400
X and Y values for vertices 4 -1400, 1400
3 Click Tool Position Supervision in the Modify ribbon tab and set the
properties.
Parameter Value
Activation PermanentlyActive
Function active status No signal
Violation action Stop category Category1Stop
Signal No signal
Settings Checked the Include upper arm
geometry and Allow inside
check boxes.
4 In the Visual SafeMove browser, right-click Tool Speed Supervisions and

choose Create Global Tool Speed Supervision.
Parameter Value
Activation ISH_Supervise_TSP
Function active status ISH_TSP_Active
Signal ISH_TSP_Viol
Settings Max speed (mm/s) 250.000
Min speed (mm/s) Leave blank
5 In the Visual SafeMove browser, right-click Stand Still Supervisions and

choose Create Global Stand Still Supervision.
Parameter Value
Activation ISH_Supervise_SST
Function active status ISH_SST_Active
Signal ISH_SST_Viol
Tolerances Enabled for all joints and remain
default tolerance values.
Uploading the settings to the controller

1 In the Visual SafeMove ribbon tab, click Controller in the Configuration
group.
2 Click Write to controller.
The configurations are uploaded to the controller after the controller restarts.

3.7.5.1 Configuration of one PROFINET-base laser scanner (RobotWare 7.5 or earlier)
3.7.5 Speed control
Preparing the robot system

Required options for system setup
When setting up the system using the Modify Installation function in RobotStudio,
select the options [3020-2] PROFINET Device, [3023-2] PROFIsafe Device and
[3043-3] SafeMove Collaborative, and the correct robot variant. The option Drive
System IRB Small Robot is selected automatically after the robot type is determined.
Supported parameters for connections to scanner and PLC

Both the laser scanner and the PLC uses a PC-based software tool to configure
the connection parameters that are used to connect to the OmniCore system. The
supported parameters of the OmniCore system are predefined in the configuration
file which could be loaded to after the Collaborative Speed Control add-in is
installed, see Information about Collaborative Speed Control add-in on page 98.
The I/O configuration can be seen using I/O Engineering Tool in RobotStudio.
The following list shows the configuration parameters. They need to be correctly
configured in the software tools to enable communication between the scanner,
PLC, and OmniCore system.
• After the robot system is set up, the default IP address of the WAN port is
automatically configured as 192.168.10.10/24. Make sure the scanner and
PLC are also configured in the 192.168.10.XXX segment.
• In RobotStudio, open the configuration editor: Controller > Configuration >
I/O Engineering Tool, and get the:
- PROFIsafe parameter values
Device slot Parameter Value
SDO Source address 2
SDO Destination address 3
SDI Source address 4
SDI Destination address 5
- device mapping information

Signal name Device Category Device Device slot
mapping
(default)
ProtectingArea 64 ProfiSafe OmniCore_Internal SDI
WarningArea 65 ProfiSafe OmniCore_Internal SDI
ProtectingAreaSST 66 ProfiSafe OmniCore_Internal SDI
WarningAreaTSP 67 ProfiSafe OmniCore_Internal SDI
SafetyCommunica- 68 ProfiSafe OmniCore_Internal SDI
tionEnable

Continued
• The PROFINET device name of the controller must be set to

omnicoreprofisafe.
Tip
Previous device mapping information is based on the default setting that is

configured with 8 byte DI, 8 byte DO, 8 byte SDI and 8 byte SDO. The LED control
module needs to occupy 5 bits in the 8 byte SDI for the signals.
If the 8 byte DI is insufficient for the actual application, users can delete the
default DI device slot and add a larger one, then, reallocate the device mapping
addresses to the five signals. The signal names and corresponding functions
must be the same as that defined in the default setting. This is to make sure that
the LED control module can still work properly.
Take the expansion to 256 byte DI and 256 byte DO as an example. If the user
expands both DI and DO to 256 byte, the possible device mapping addresses
for the ProtectingArea, WarningArea, ProtectingAreaSST, WarningAreaTSP and
SafetyCommunicationEnable signals in 8 byte SDI device slot should be 2048,
2049, 2050, 2051 and 2052, respectively.
GSD file
The GSD file, GSDML-V2.xx-ABB-Robotics-OmniCore-YYYYMMDD.xml, can be
obtained from the RobotStudio or the OmniCore controller.
• In the RobotWare installation folder in RobotStudio:
...\DistributionPackages\ABB.RobotWare-x.x.x-xxx\RobotPackages
\RobotControl_x.x.xxx\utility\service\GSDML\
• On the OmniCore Controller:
...\products\RobotControl_x.x.x\utility\service\GSDML\

Continued
Configuring the laser scanner

Protection fields
Four protection fields are defined to provide a progressive safety protection. The
following figure illustrates the field ranges.
A
B
C
D
xx2100000165
Field Device Lamp col- Description

mapping or
(default)
A WarningArea 65 Yellow The warning area field defines the largest
range, but it shall be within the scanning
range of the scanner.
Within in this field range, the lamp unit on
the process hub lights up yellow, and the
robot movement speed reduces to a lower
speed that is set by the user.
B WarningAreaTSP 67 Yellow Within in this field range, the lamp unit still
lights up yellow, but Tool Speed Supervi-
sion (TSP) is enabled. If the robot moves
in the speed that is out of the defined
range for TSP, the motor is off.
For details about TSP, see Application
C ProtectingArea 64 Red Within this field range, the lamp unit turns
to red and the robot movement speed is
reduced to 0. The robot stands still.

Continued

mapping or
(default)
D ProtectingAre- 66 Red The protecting stop SST field defines the
aSST smallest range. However, this range shall
be larger than the minimum stopping dis-
tance on the basis of the response time
for a small scanning cycle time. For details
about how to calculate the range, see the
user manual from the vendor. For details
about the stopping distance and response
time, see Product specification - Robot
stopping distances according to ISO
10218-1.
Within this field range, the lamp unit still
lights up red, but Stand Still Supervision
(SST) is enabled. If the robot axes move
exceeding the maximum range setting in
SST, the motor is off.
For details about SST, see Application
Configuration procedure
Before starting the configuration, obtain the microScan 3 Core - PROFINET GSDML
file and the software tool Safety Designer® from SICK's website first. Make sure
both the file and the software tool are in the latest versions.
Detailed procedures about how to configure the laser scanner are detailed in SICK
microScan3 Siemens PLC integration instruction manual - TIA Portal and SICK
microScan3 Siemens PLC integration instruction manual - SIMATIC Step 7.
Following described roughly:
1 Connect the laser scanner to the PLC and controller.
See the physical connection in Connecting the laser scanner(s) on page 80.
2 Open configuration software tool Safety Designer®.
3 Set IP address and PROFINET name in Configuration > Addressing.
• The scanner IP address must be in the same network segment with
the PLC and controller, that is, 192.168.10.XXX.
• The PROFINET name must be the same in the PLC configuration.
4 Set F-destination address to 12 in PROFINET area in Configuration >
Protocol Settings.
5 Define the four protection fields in Configuration > Fields.
6 Define the source for input signals of the scanner and configure basic settings
for the inputs and outputs in Configuration > Inputs and outputs.
The Use one input source checkbox must be selected and choose Rx:
Process image (6 Bytes) from the drop-down list.
7 Create monitoring cases and assign the fields that are to be monitored to
each monitoring cases in Configuration > Monitoring cases.

Continued
Configuring the PLC

The safety PLC connecting to the laser scanner and controller must support
PROFIsafe and can act as a master. Before configuration, make sure the PLC is
loaded with the GSD files of the controller and laser scanner.
Detailed procedures about how to add an external device to the PLC and how to
configure detailed settings, see the user manual from the vendor. Following lists
the necessary settings during PLC configuration:
• Add the scanner to the PLC by adding a mS3 6Byte In/Out PROFIsafe V2.6.1
module.
The parameters f_dest_address and f_source_address are set to 12 and 1,
respectively.
• Add the controller to the PLC by adding the DI 8 bytes, DO 8 bytes, SDI 8
bytes and SDO 8 bytes modules.
The parameters f_dest_address and f_source_address for the SDI are set to
3 and 2, respectively, and for the SDO are set to 5 and 4, respectively.
• Make sure the address for the SDO signal is the first address of SDO 8 bytes
slot.
• Create variables.
Name Type Example address i
ProtectingTrigger Bool %I3.0
WarningTrigger Bool %I4.1
ProtectingSSTTrigger Bool %I3.2
WarningTSPTrigger Bool %I3.3
ProtectingArea Bool %Q68.0
WarningArea Bool %Q68.1
ProtectingAreaSST Bool %Q68.2
WarningAreaTSP Bool %Q68.3
SafetyCommunicationEnable Bool %Q68.4
ActivateScanner Bool %Q3.0
i %I3.X and %I4.X are the addresses of the laser scanner; %Q68.X is the address of the
OmniCore controller.
%Q3.0 is for activating the monitoring cases of the laser scanner.
• Check the communication between the PLC and controller is well and activate
the laser scanner; set up the communication between the laser scanner, PLC
and OmniCore controller.
With RobotStudio
Basic steps for configuring SafeMove are as follows:
1 Make some initial preparations.
2 Configure system parameters.
3 Set the input and output size and name of the PROFINET internal device.

Continued
For CRB 1100, required settings for communication between laser scanner,
PLC and OmniCore controller are predefined in the configuration file.
4 Set up safety user grants.
Users must have access grants to lock safety controller configurations, safety
services and software synchronization.
5 Configure robot properties.
6 Configure the synchronization position.
7 Configure the SafeMove tool definitions.
8 Configure safe I/O signals.
Note
For the first time configuring safe I/O signals using Visual SafeMove, make
sure the I/O Engineering Tool is opened first. In this case, the configured
safe I/O signals can be displayed in the Visual SafeMove window.
9 Configure zones and/or ranges.

10 Configure the supervision functions.
Tool Speed Supervision (TSP) and Stand Still Supervision (SST) must be
configured.
11 Configure other functions.
12 Load the configuration to the safety controller.
13 Restart the robot controller.
Detailed configuration procedures are specified in Application manual - Functional
safety and SafeMove.
With FlexPendant
1 Log in the FlexPendant.
The user logging in must have access grants to lock safety controller
configurations, safety services and software synchronization.
2 Tap Settings on the home page.
3 Tap Safety Controller.
4 Tap Synchronization in the left pane.
5 Jog the robot to match the Actual Positions values with the Sync Positions
values. Make sure they are the same.
6 Tap Synchronize.

3.7.5.2 Configuration of one PROFIsafe-based laser scanner (RobotWare 7.6 or later and PLC acting
as Master)
3.7.5.2 Configuration of one PROFIsafe-based laser scanner (RobotWare 7.6 or later

and PLC acting as Master)

select the options [3020-2] PROFINET Device, [3023-2] PROFIsafe Device, [3043-3]
SafeMove Collaborative and [3051-1] Profisafe Package, and the correct robot
variant. The option Drive System IRB Small Robot is selected automatically after
the robot type is determined.
Supported parameters for connections to scanner and PLC

Both the laser scanner and the PLC uses a PC-based software tool to configure
the connection parameters that are used to connect to the OmniCore system. The
file which could be loaded after the Collaborative Speed Control add-in is installed,
see Information about Collaborative Speed Control add-in on page 98. The I/O
configuration can be seen using I/O Engineering Tool in RobotStudio.
configured in the software tools to enable communication between the scanner,
automatically configured as 192.168.10.10/24. Make sure the scanner and

mapping
(default)
tionEnable

omnicoreprofisafe.

as Master)
Continued
GSD file

Protection fields
Two protection fields are defined to provide a progressive safety protection. The
xx2200000301

mapping or
(default)
B ProtectingArea 0 Red Within this field range, the lamp unit turns

as Master)
Continued
Detailed procedures about how to configure the laser scanner are detailed in SICK
microScan3 Siemens PLC integration instruction manual - TIA Portal and SICK
microScan3 Siemens PLC integration instruction manual - SIMATIC Step 7.
1 Connect the laser scanner to the PLC and controller.
Protocol Settings.
5 Define the two protection fields in Configuration > Fields.
Configuring the PLC

The safety PLC connecting to the laser scanner and controller must support
loaded with the GSD files of the controller and laser scanner.
• Add the scanner to the PLC by adding a mS3 6Byte In/Out PROFIsafe V2.6.1
module.
The parameters f_dest_address and f_source_address are set to 12 and 1,
respectively.
slot.

as Master)
Continued
ProtectingArea Bool %Q68.0
WarningArea Bool %Q68.1
i %I3.X and %I4.X are the addresses of the laser scanner; %Q68.X is the address of the
OmniCore controller.
%Q3.0 is for activating the monitoring cases of the laser scanner.
To enable SafeMove, perform the following procedure:
Make sure the user logged in have access grants to lock safety controller
2 Tap SafeMove on the home page.
3 Tap Load in the pop-up message box to confirm loading of template SafeMove
configuration files.
The controller restarts.
4 After the controller is restarted, tap Settings on the home page.
values.
Make sure the values are the same.
8 Tap Synchronize.

3.7.5.3 Configuration of two PROFIsafe-based laser scanners (RobotWare 7.6 or later and PLC acting
as Master)

later and PLC acting as Master)

select the options [3020-2] PROFINET Device, [3023-2] PROFIsafe Device, [3043-3]
SafeMove Collaborative and [3051-3] Dual Profisafe Package, and the correct robot
variant. The option Drive System IRB Small Robot is selected automatically after
the robot type is determined.
Supported parameters for connections to scanners and PLC

Both laser scanners and the PLC uses a PC-based software tool to configure the
connection parameters that are used to connect to the OmniCore system. The
file which could be loaded after the Collaborative Speed Control add-in is installed,
see Information about Collaborative Speed Control add-in on page 98. The I/O
configuration can be seen using I/O Engineering Tool in RobotStudio.
configured in the software tools to enable communication between the scanners,
automatically configured as 192.168.10.10/24. Make sure the scanners and

mapping
(default)
tionEnable

omnicoreprofisafe.

as Master)
Continued
GSD file

Protection fields
xx2200000301

mapping or
(default)

as Master)
Continued
Detailed procedures about how to configure the laser scanners are detailed in
SICK microScan3 Siemens PLC integration instruction manual - TIA Portal and
SICK microScan3 Siemens PLC integration instruction manual - SIMATIC Step 7.
1 Connect the laser scanners to the PLC and controller.
3 Set IP address, F-destination and PROFINET name in Configuration >
Addressing.
• The two scanners must be set to different IP address, F-destination
and PROFINET name.
4 Set F-destination address to 12 for the first scanner and to 13 for the second
scanner, in PROFINET area in Configuration > Protocol Settings.
5 Define the two protection fields for each scanners in Configuration > Fields.
6 Define the source for input signals of each scanner and configure basic
settings for the inputs and outputs in Configuration > Inputs and outputs.
Configuring the PLC

The safety PLC connecting to the laser scanners and controller must support
loaded with the GSD files of the controller and laser scanners.
• Add two scanners to the PLC by adding two mS3 6Byte In/Out PROFIsafe
V2.6.1 modules.
- The parameters f_dest_address and f_source_address are set to 12 and 1,
for the first scanner, respectively.
- The parameters f_dest_address and f_source_address are set to 13 and 1,
for the second scanner, respectively.

as Master)
Continued
slot.
ProtectingTrigger1 Bool %I14.0
WarningTrigger1 Bool %I15.1
ProtectingArea ii Bool %Q68.0
WarningArea iii Bool %Q68.1
ActivateScanner1 Bool %Q14.0
i %I3.X, %I4.X, %I14.X and %I15.X are the addresses of laser scanners; %Q68.X is the address
of the OmniCore controller.
%Q3.0 and %Q14.0 are for activating the monitoring cases of the laser scanners.
ii Value of ProtectingArea depends on logic AND value of ProtectingTrigger and
ProtectingTrigger1.
iii Value of WarningArea depends on logic AND value of WarningTrigger and WarningTrigger1.
values.
8 Tap Synchronize.

3.7.5.4 Configuration of one PROFIsafe-based laser scanner (RobotWare 7.10 or later and OmniCore
acting as Master)

later and OmniCore acting as Master)

select the options [3020-1] PROFINET Controller, [3023-1] PROFIsafe Controller,
[3043-3] SafeMove Collaborative and [3051-1] Profisafe Package, and the correct
robot variant. The option Drive System IRB Small Robot is selected automatically
after the robot type is determined.
Configuring supported parameters of the robot system

The laser scanner needs to use a PC-based software tool to configure the
supported parameters of the OmniCore system are configure using I/O Engineering
Tool in RobotStudio. Use the following procedure to perform the configuration:
1 Start RobotStudio and connect the controller.
• The user account logging in the controller must be granted with the
Safety Services permission.
• The write access to the controller is requested.
2 In the Controller tab, click I/O Engineering.
The I/O Engineering window is displayed.
3 In the Configuration tab page on the left pane of the window, right-click
PROFINET under I/O system and select Scan Network.
The connected laser scanner is displayed.
4 Right-click on the laser scanner and choose Add as.
The laser scanner is added under Controller in the Configuration tab page.
Note
Two device names are displayed in the list by default. You shall right-click
on the device name mS3 12Byte In/Out PROFIsafe V2.6.1 and choose
Delete to delete it. The name may vary according to the actual laser scanner
connected.
5 Click the laser scanner with the asterisk(*) mark, and then in the Device
Catalog tab page on the right pane of the window, double-click mS3 6Byte
In/Out PROFIsafe V2.6.1.
6 In the displayed Signal Editor tab page, add signals with following settings.
Name Type of Signal Device Mapping i Default value
ActiveDevice1 Digital Output 8 1
ProtectingArea1 Digital Input 17 0
WarningArea1 Digital Input 8 0
i The mappings are only for examples. Refer to the cut-off setting defined in the Safety
Designer software and enter the actual value.

acting as Master)
Continued
A new device name mS3 6Byte In/Out PROFIsafe V2.6.1 is displayed under
the scanner in the Configuration tab page.
7 Click the new device name and check the settings in the Properties tab page
on the right pane of the window.
Make sure the Destination value is the same as the F-Destination address
value for the scanner in the Safety Designer software.
8 In the I/O Engineering tab, click Cross Connections in the Configuration
group, and check the created signals.
Make sure the created signals are in the same name as the displayed signals.
9 In the I/O Engineering tab, click Write Config to write the configurations to
the controller.
10 Restart the controller.
11 After the controller is restarted, check the laser scanner name in the RAPID
program InternalSpeedHandling_User in task T_ROB1, and make sure it is
consistent with the name that the user defines for the laser scanner.
If the names are inconsistent, use the following steps to modify:
a In the Controller pane, double-click the RAPID program
InternalSpeedHandling_User in task T_ROB1.
The RAPID program is displayed in the right pane.
b Find the parameter Scanner1 and modify its value to the user-defined
laser scanner name.

acting as Master)
Continued

Protection fields
xx2200000301

mapping or
(default)
Detailed procedures about how to configure the laser scanner are detailed in
Operating instructions microScan3 - PROFINET. Following described roughly:
1 Connect the laser scanner to the PC using a network cable.

acting as Master)
Continued

The scanner IP address must be in the same network segment with the
controller, that is, 192.168.10.XXX.
Protocol Settings.
3 In the Visual SafeMove window, configure SafeMove function as instructed
in Configuration of SafeMove using Visual SafeMove in RobotStudio on
page 118.

3.7.5.5 Configuration of two PROFIsafe-based laser scanners (RobotWare 7.10 or later and OmniCore
acting as Master)

later and OmniCore acting as Master)

select the options [3020-1] PROFINET Controller, [3023-1] PROFIsafe Controller,
[3043-3] SafeMove Collaborative and [3051-3] Dual Profisafe Package, and the
correct robot variant. The option Drive System IRB Small Robot is selected
automatically after the robot type is determined.
Configuring supported parameters of the robot system

The laser scanners need to use a PC-based software tool to configure the
supported parameters of the OmniCore system are configure using I/O Engineering
Tool in RobotStudio. Use the following procedure to perform the configuration:
2 In the Controller tab, click I/O Engineering.
The I/O Engineering window is displayed.
3 In the Configuration tab page on the left pane of the window, right-click
PROFINET under I/O system and select Scan Network.
The connected laser scanners are displayed.
4 Right-click one of the laser scanners and choose Add as.
The laser scanner is added under Controller in the Configuration tab page.
Note
Two device names are displayed in the list by default. You shall right-click
on the device name mS3 12Byte In/Out PROFIsafe V2.6.1 and choose
Delete to delete it. The name may vary according to the actual laser scanner
connected.
5 Click the laser scanner with the asterisk(*) mark, and then in the Device
Catalog tab page on the right pane of the window, double-click mS3 6Byte
In/Out PROFIsafe V2.6.1.
6 In the displayed Signal Editor tab page, add signals with following settings.

acting as Master)
Continued
A new device name mS3 6Byte In/Out PROFIsafe V2.6.1 is displayed under
the scanner in the Configuration tab page.
7 Click the new device name and check the settings in the Properties tab page
on the right pane of the window.
Make sure the Destination value is the same as the F-Destination address
value for the scanner in the Safety Designer software.
8 In the I/O Engineering tab, click Cross Connections in the Configuration
group, and check the created signals.
Make sure the created signals are in the same name as the displayed signals.
9 Repeat steps 4 to 8 to add the other laser scanner, for which the signal
settings shall be as follows.
10 In the I/O Engineering tab, click Write Config to write the configurations to
the controller.
12 After the controller is restarted, check the laser scanner name in RAPID
program InternalSpeedHandling_User in task T_ROB1, and make sure it is
consistent with the name that the user defines for the laser scanner.
If the names are inconsistent, use the following steps to modify:
a In the Controller pane, double-click the RAPID program
InternalSpeedHandling_User in task T_ROB1.
The RAPID program is displayed in the right pane.
b Find the parameters Scanner1 and Scanner2, and modify their values
to the user-defined laser scanner names.

acting as Master)
Continued

Protection fields
xx2200000301

mapping or
(default)
Operating instructions microScan3 - PROFINET . Following described roughly:
1 Connect the laser scanner to the controller using a network cable.

acting as Master)
Continued

3 Set IP address, F-destination and PROFINET name in Configuration >
Addressing.
the controller, that is, 192.168.10.XXX.
• The two scanners must be set to different IP address, F-destination
and PROFINET name.
4 Set F-destination address to 12 for the first scanner and to 13 for the second
scanner, in PROFINET area in Configuration > Protocol Settings.
3 In the Visual SafeMove window, configure SafeMove function as instructed
in Configuration of SafeMove using Visual SafeMove in RobotStudio on
page 118.

3.7.5.6 Configuration of one SafetyIO-base laser scanner (RobotWare 7.6 or later)

select the options [3043-3] SafeMove Collaborative and [3051-2] IO Package, and
the correct robot variant. The option Drive System IRB Small Robot is selected
Supported parameters for connections to scanners and scalable I/O device

The laser scanner uses a PC-based software tool to configure the connection
parameters that are used to connect to the OmniCore system. The supported
parameters of the OmniCore system are predefined in the configuration file which
could be loaded to the system after the Collaborative Speed Control add-in is
The following table lists the device mapping information of Scalable_IO signals,
which are automatically configured after the add-in installation.
Signal name Device mapping Device
ABB_Scalable_IO_0_DI1 i 0 ABB_Scalable_IO
ABB_Scalable_IO_0_DI3 ii 2 ABB_Scalable_IO
i Value of ProtectingArea depends on logic AND value of ABB_Scalable_IO_0_DI1 and
ABB_Scalable_IO_0_DI2. For definition of ProtectingArea, see Configuring the laser scanner on
page 146.
ii Value of WarningArea depends on logic AND value of ABB_Scalable_IO_0_DI3 and
ABB_Scalable_IO_0_DI4. For definition of WarningArea, see Configuring the laser scanner on
page 146.

Continued

Protection fields
xx2200000301
Field Lamp color Description

A WarningArea Yellow The warning area field defines the largest range,
but it shall be within the scanning range of the
scanner.
Within in this field range, the lamp unit on the
process hub lights up yellow, and the robot
movement speed reduces to a lower speed that
is set by the user.
B ProtectingArea Red Within this field range, the lamp unit turns to red
and the robot movement speed is reduced to 0.
The robot stands still.
Before starting the configuration, obtain the software tool Safety Designer® from
SICK's website first. Make sure the software tool is in the latest version.
Operating instructions microScan3 - Pro I/O from the vendor. Following described
the procedure roughly:
2 Set IP address in Configuration > Addressing.
Make sure the scanner IP address is in the same network segment with the
PC used for configuring the scanner.

Continued
3 Define the two protection fields for the scanner in Configuration > Fields.
5 Select one OSSD pair from the Signals panel to pin1 and pin2, and select
another OSSD pair to pin3 and pin4.
The two OSSD pairs will be used for defining the monitoring cases.
7 Refer to the following table to obtain the pins defined to OSSD pairs. The
pins are from a 17-pin cable that will be used to connect the laser scanner
and scalable I/O device.
Pin Wiring color Name Function
1 Brown OSSD1A OSSD pair 1, OSSD A
2 Blue OSSD1B OSSD pair 1, OSSD B
3 White OSSD2A OSSD pair 2, OSSD A
4 Green OSSD2B OSSD pair 2, OSSD B
17 White with grey 0 V DC 0 DC
8 Connect the laser scanner to scalable I/O device with the defined pins.
Pin in cable Pin position number in X2 connector of
the device i
Pin1 (OSSD1A) D101+
Pin2 (OSSD1B) DI02+
Pin3 (OSSD2A) DI03+
Pin4 (OSSD2B) DI04+
Pin17 Circuit of D101-, D102-, D103- and D104-
i For detailed information of pin definitions in connector X2 Digital inputs of the scalable I/O
device DSQC1042, see the product specification of the controller and Application
Configuring the scalable I/O device

Detailed procedures about how to connect and configure the scalable I/O device
DSQC1042 are specified in Application manual - Scalable I/O. Following provides
a rough procedure:
1 Make sure that the laser scanner and scalable I/O device is connected as
instructed in previous configuration procedure of laser scanner.
2 Connect the process power supply to connector X1 of the scalable I/O device
via pin locations PWR DO and GND DO.
3 Connect the logic power supply to connector X4 of the scalable I/O device
via pin locations PWR and GND.
4 Connect the Ethernet cable from the robot controller to connector X5.

Continued
5 Log in the RobotStudio using the admin use account and configure the device
to make sure the device communication works.
a Click the Controller tab and, in the Controller pane, choose I/O System
> EtherNetIP.
Information of three devices can be observed:
- CabinetIO is used for the I/O device DSQC1030, and the
communication status is normal.
- ABB_Scalable_IO and ABB_Scalable_IO1 are used for the I/O device
DSQC1042, and the communication status is abnormal.
b Check the IP address and serial numbers associated with
ABB_Scalable_IO and ABB_Scalable_IO1, which will display as follows.
Device name IP address Serial number
ABB_Scalable_IO 192.168.125.130 0
ABB_Scalable_IO1 192.168.125.131 Actual serial number of
the device
c Right-click ABB_Scalable_IO1 and choose Configure from the shortcut

menu.
d In the displayed dialog box, choose the Configure as replacement
device option and select ABB_Scalable_IO from the drop-down list.
e Remove the texts in the Create new I/O signals using name prefix
text box and then click OK.
Information of two devices can be observed, CabinetIO and
ABB_Scalable_IO. Communication status of ABB_Scalable_IO will turn
to normal after the SafeMove template file is uploaded using the
SafeMove configurator app.
Note
The configuration could also be done using the I/O application in

FlexPendant.
Note

Continued
values.
8 Tap Synchronize.

3.7.5.7 Configuration of two SafetyIO-base laser scanners (RobotWare 7.6 or later)

select the options [3043-3] SafeMove Collaborative and [3051-4] Dual IO Package,
and the correct robot variant. The option Drive System IRB Small Robot is selected
Supported parameters for connections to scanners and scalable I/O device

The laser scanners use a PC-based software tool to configure the connection
parameters that are used to connect to the OmniCore system. The supported
parameters of the OmniCore system are predefined in the configuration file which
could be loaded to the system after the Collaborative Speed Control add-in is
The following table lists the device mapping information of Scalable_IO signals,
which are automatically configured after the add-in installation.
Signal name Device mapping Device
i Value of ProtectingArea depends on logic AND value of ABB_Scalable_IO_0_DI1,
ABB_Scalable_IO_0_DI2, ABB_Scalable_IO_0_DI5 and ABB_Scalable_IO_0_DI6. For definition of
ProtectingArea, see Configuring the laser scanner on page 151.
ii Value of WarningArea depends on logic AND value of ABB_Scalable_IO_0_DI3,
ABB_Scalable_IO_0_DI4, ABB_Scalable_IO_0_DI7 and ABB_Scalable_IO_0_DI8. For definition of
WarningArea, see Configuring the laser scanner on page 151.

Continued

Protection fields
xx2200000301
Field Lamp color Description

A WarningArea Yellow The warning area field defines the largest range,
but it shall be within the scanning range of the
scanner.
Within in this field range, the lamp unit on the
process hub lights up yellow, and the robot
movement speed reduces to a lower speed that
is set by the user.
B ProtectingArea Red Within this field range, the lamp unit turns to red
and the robot movement speed is reduced to 0.
The robot stands still.
Before starting the configuration, obtain the software tool Safety Designer® from
SICK's website first. Make sure the software tool is in the latest version.
Detailed procedures about how to configure the laser scanners are detailed in
Operating instructions microScan3 - Pro I/O from the vendor. Following described
the procedure roughly:
2 Set IP address in Configuration > Addressing.
• Make sure the scanner IP addresses are in the same network segment
with the PC used for configuring the scanner.

Continued
• The two scanners must be set to different IP addresses.

3 Define the two protection fields for each scanner in Configuration > Fields.
4 Define the source for input signals of each scanner and configure basic
settings for the inputs and outputs in Configuration > Inputs and outputs.
5 For both scanners, select one OSSD pair from the Signals panel to pin1 and
pin2, and select another OSSD pair to pin3 and pin4.
The two OSSD pairs will be used for defining the monitoring cases.
7 Refer to the following table to obtain the pins defined to OSSD pairs. The
pins are from a 17-pin cable that will be used to connect a laser scanner and
scalable I/O device.
Pin Wiring color Name Function
1 Brown OSSD1A OSSD pair 1, OSSD A
2 Blue OSSD1B OSSD pair 1, OSSD B
3 White OSSD2A OSSD pair 2, OSSD A
4 Green OSSD2B OSSD pair 2, OSSD B
17 White with grey 0 V DC 0 DC
8 Connect the laser scanners to safety module with the defined pins.
Scanner Pin in cable Pin position number in X2
connector of the device i
Scanner 1 Pin1 (OSSD1A) D101+
Pin2 (OSSD1B) DI02+
Pin3 (OSSD2A) DI03+
Pin4 (OSSD2B) DI04+
Pin17 Circuit of D101-, D102-, D103-
and D104-
Scanner 2 Pin1 (OSSD1A) D105+
Pin2 (OSSD1B) DI06+
Pin3 (OSSD2A) DI07+
Pin4 (OSSD2B) DI08+
Pin17 Circuit of D105-, D106-, D107-
and D108-
i For detailed information of pin definitions in connector X2 Digital inputs of the scalable I/O
device DSQC1042, see the product specification of the controller and Application
Configuring the scalable I/O device

Detailed procedures about how to connect and configure the scalable I/O device
DSQC1042 are specified in Application manual - Scalable I/O. Following provides
a rough procedure:
1 Make sure that the laser scanner and scalable I/O device is connected as
instructed in previous configuration procedure of laser scanner.

Continued
2 Connect the process power supply to connector X1 of the scalable I/O device
via pin locations PWR DO and GND DO.
3 Connect the logic power supply to connector X4 of the scalable I/O device
via pin locations PWR and GND.
4 Connect the Ethernet cable from the robot controller to connector X5.
5 Log in the RobotStudio using the admin use account and configure the device
to make sure the device communication works.
a Click the Controller tab and, in the Controller pane, choose I/O System
> EtherNetIP.
Information of three devices can be observed:
- CabinetIO is used for the I/O device DSQC1030, and the
communication status is normal.
- ABB_Scalable_IO and ABB_Scalable_IO1 are used for the I/O device
DSQC1042, and the communication status is abnormal.
b Check the IP address and serial numbers associated with
ABB_Scalable_IO and ABB_Scalable_IO1, which will display as follows.
Device name IP address Serial number
ABB_Scalable_IO 192.168.125.130 0
ABB_Scalable_IO1 192.168.125.131 Actual serial number of
the device
c Right-click ABB_Scalable_IO1 and choose Configure from the shortcut

menu.
d In the displayed dialog box, choose the Configure as replacement
device option and select ABB_Scalable_IO from the drop-down list.
e Remove the texts in the Create new I/O signals using name prefix
text box and then click OK.
Information of two devices can be observed, CabinetIO and
ABB_Scalable_IO. Communication status of ABB_Scalable_IO will turn
to normal after the SafeMove template file is uploaded using the
SafeMove configurator app.
Note
The configuration could also be done using the I/O application in

FlexPendant.
Note

Continued
values.
8 Tap Synchronize.

3.7.5.8 Speed control strategies
General
The speed control of CRB 1100 is affected by several factors, such as, the
RobotWare version, the speed setting in the FlexPendant, the speed setting in
motion instruction and the SpeedRefresh value. Users in different protection
fields defined for laser scanner to monitor and perform different program execution
actions may result in different movement speed. This section describes the speed
control strategies for typical scenarios.
Strategies (RobotWare 7.5)

Users in Protecting area
xx2100000512

Continued
Users in Warning area
xx2100000513
SafeMove triggered but SST/TSP not configured
xx2100000514

Continued
Strategies (RobotWare 7.6 or later)

Users in Protecting area
xx2200000302
Users in Warning area
xx2200000303

3.7.6 Robot status indication
Description
The lamp unit on process hub of CRB 1100 indicates robot status in four colors.
Operators should always be aware of the indicator color and handle the situation
correspondingly.
Cabling
The lamp unit cabling is integrated in the CP/CS cable. Do not use other types of
CP/CS cables that are not provided by ABB; otherwise, the lamp unit will not work.
See Robot cabling and connection points on page 89.
The cable end connecting the manipulator connects to the R1.C1 connector on
the robot base; the other end of the cable is divided to two connectors, which
connect to the X1 connector of the base I/O device (DSQC 1030) and X19 connector
on the controller respectively.
The following figure illustrates the lamp unit cabling connection between the
manipulator base and controller with base I/O module configured. For more details
about cabling, see the circuit diagram of the manipulator.
A B C
xx2100000291
A R1.C1 connector on robot

base
B X1 connector of I/O module Pins GND, DO1, DO2 and DO3 are occupied for
on controller lamp unit
C X19 connector on controller Pins 1 and 2 are occupied for lamp unit
Functionality
Color Manual mode Automatic mode Manual full speed mode

White Standby (in motor on/off state and program is stopped, available for users to
perform next actions)
Green Program is executing
Yellow Lead-through function is Yellow warning area is triggered (manipulator speed
enabled will be limited according to the actual configured value)

Continued
Color Manual mode Automatic mode Manual full speed mode

Red Emergency stop or error is Emergency stop, error is raised or red protecting area
raised is triggered.
For RobotWare 7.5 or earlier, the manipulator will re-
duce to 0% speed and stands still.
For RobotWare 7.6 or later, the speed shown on the
FlexPendant remains but the manipulator will stand
still.

3.7.7 Use cases of safety configurations
General
Configurations of lamp indicator and speed control are allowed to be modified in
RAPID programs, which are loaded to the system after the Collaborative Speed
Control add-in is installed.
Note
Safety configurations can only be modified for robots running in RobotWare 7.6
and later versions.
Modified configuration must always be validated to verify that the desired safety
is achieved. If no validation is performed, or the validation is inadequate, the
configuration cannot be relied on for personal safety.
Modifying lamp indicator colors

RGB of the LED lamp is controlled by values defined in RAPID instruction
SWIFTI_SetCustomizedLEDColor in routine SWIFTI_LedMain, which can affect
the color that the lamp shows. The routine exists in the system module SWIFTI_Main
of task T_SWIFTI_LED.
xx2200000434
The following table lists the logical value combinations and corresponding lamp
colors.
Color Parameter value 1 Parameter value 2 Parameter value 3
White TRUE TRUE TRUE
Blue FALSE FALSE TRUE
Green FALSE TRUE FALSE
Red TRUE FALSE FALSE
Yellow TRUE TRUE FALSE
Cyan FALSE TRUE TRUE
Purple TRUE FALSE TRUE

Continued
Deactivating the SpeedHandling function
Note
Modified configuration must always be validated to verify that the desired safety
is achieved. If no validation is performed, or the validation is inadequate, the
configuration cannot be relied on for personal safety.
The SpeedHandling function is activated by default after the Collaborative Speed
Control add-in is installed and the SafeMove template is loaded. The function is
used to enable or disable speed-related actions for speed control.
It is possible to use the following procedure to deactivate the SpeedHandling
function based on risk assessment of the final application:
1 In RobotStudio, open the RAPID program InternalSpeedHandling_User in
task T_ROB1.
2 Navigate to the function ISH_b_FunctionlityIsUsed and set its value from
default TRUE to FALSE.
xx2200000435
3 Save the change and apply to the controller.

SafeMove configurations also affect the speed control on the robot to achieve
further safety. SafeMove is still functional after the SpeedHandling function in
RAPID program is deactivated.
Use the following procedure to disable the speed control function provided by
SafeMove:
1 Open the RobotStudio.
2 Log in the controller using the Admin account and request the write access.
3 In the Controller tab, choose Visual SafeMove from the Safety group in the
Configuration category.
4 In the Visual SafeMove tab, click Safe IO Configurator in the Configuration
group.

Continued
5 In the displayed Safe IO Configuration window, go to the signal

ISH_UserMODE_bNot_IntemitCollab in the global signal list and set the
value to 1.
xx2200000436
6 Apply the configuration to the controller by clicking Write to Controller in

the Controller group in the Configuration category.
If the SpeedHandling function requires to be reactivated after deactivation, make
sure:
• the signal ISH_UserMODE_bNot_IntemitCollab in SafeMove configuration
is set to 0, and,
• the function ISH_b_FunctionlityIsUsed in RAPID program is set to TRUE.
Changing the speed limit when WarningArea is triggered

When users enter the warning area, the robot speed is limited to 250 mm/sec by
default. Use the following procedure to change the speed limit based on risk
assessment of the final application:
1 In RobotStudio, open the RAPID program InternalSpeedHandling_User in
task T_ROB1.
2 Navigate to the function ISH_n_Speed_In_WarningArea_mm_s and set its
value from default 250 to any required value.
xx2200000437
3 Save the change and apply to the controller.

The speed limit can also be changed in SafeMove configurations using the following
procedure:

Continued
4 In the left pane of the window, choose Global_TSP under the Tool Speed
Supervisions from the navigation tree.
xx2200000438
5 In the Visual SafeMove Properties window, set the Max speed (mm/s) in
the Speed limits area to a required value.
xx2200000439


Continued
Changing the execution delay time in template SafeMove configuration file

Configurations of SST and TSP are predefined in the template SafeMove
configuration file as two global signals ISH_AtUser_Period_ms_Until_SST and
ISH_AtUser_Period_ms_Until_TSP.
• ISH_AtUser_Period_ms_Until_SST: default value is 650 ms. If a period of
650 ms elapses after ProtectingArea is triggered but the robot still moves,
the SST will be triggers to stop robot movement immediately.
• ISH_AtUser_Period_ms_Until_TSP: default value is 550 ms. If a period of
550 ms elapses after WarningArea is triggered but the robot still moves in a
speed larger than the defined speed limit value, the TSP will be triggered to
stop robot movement immediately.
It is possible to change the values of ISH_AtUser_Period_ms_Until_SST and
ISH_AtUser_Period_ms_Until_TSP according to application requirements using
the following procedure. The change must be based on the risk assessment of the
final application.
4 In the Visual SafeMove tab, click Safe IO Configurator in the Configuration
group.
5 In the displayed Safe IO Configuration window, go to the signals
ISH_AtUser_Period_ms_Until_SST and ISH_AtUser_Period_ms_Until_TSP
in the global signal list and reset the value as required.
xx2200000440


3.8 Test run after installation, maintenance, or repair
3.8 Test run after installation, maintenance, or repair
Safe handling
Use the following procedure after installation, maintenance, or repair, before
initiating motion.
DANGER
Initiating motion without fulfilling the following aspects, may increase the risk for
injury or cause damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Verify that no personnel is leaning on, or have their head or neck close to the robot.
6 Verify that all arm covers and paddings, if any, are properly secured to the robot.
7 If maintenance or repair has been done, verify the function of the part that was main-
tained.
8 Verify the application in the operating mode manual reduced speed.

This page is intentionally left blank
4 Maintenance
4.1 Introduction
4 Maintenance
4.1 Introduction
Structure of this chapter

This chapter describes all the maintenance activities recommended for the CRB
1100.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 17 before performing any service
work.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.
Note
If the CRB 1100 is connected to power, always make sure that the CRB 1100 is
connected to protective earth and a residual current device (RCD) before starting
any maintenance work.
• Robot cabling and connection points on page 89.

4 Maintenance
4.2.1 Specification of maintenance intervals
4.2 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 CRB 1100:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run.
The SIS used in OmniCore is further described in the Operating
manual - OmniCore.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.

4 Maintenance
4.2.2 Maintenance schedule
Scheduled and non-predictable maintenance

The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages
must be attended to immediately!
Life of each component

The inspection intervals do not specify the life of each component. Values for these
are specified in the section Expected component life on page 171
Maintenance schedule
Every 30,000 hours ii

Every 12 months
Every 36 months
Regularly i
Maintenance activities Reference
Cleaning the CRB 1100 on

Cleaning the robot x
page 172
Check for abnormal wear or
Inspecting the robot x
contamination.
Check for damages, defective or
Inspecting the laser scanners x
lack of effectiveness.
Inspecting the information labels
Inspecting the information labels x
on page 173
Inspecting the timing belt iii x Inspecting timing belts on page 176
Inspecting the robot cabling on
Inspecting the robot harness x iv
page 175
Lubricating the cable package on
Lubricating the robot harness xv
page 180
Replacing the battery pack on
Replacing the SMB battery pack x vi
page 182
Recommended to robots with the
SafeMove option. See Application
Running the Cyclic Brake Check routine vii x viii
manual - Functional safety and
SafeMove.
Overhaul of complete robot x
i "Regularly" implies that the activity is to be performed regularly, but the actual interval may not be
specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its
working environment and movement pattern. Generally, the more contaminated environment, the
shorter intervals. The more demanding movement pattern (sharper bending cable harness), the
shorter intervals.
ii Operating hours counted by the DTC = Duty time counter.
iii Axis-1 and axis-4 timing belts can be accessed and inspected only after the axis-1 and axis-4
motors are removed. It is recommended to inspect the timing belts when replacing the motors.

4 Maintenance
Continued
iv Replace when damage or cracks is detected or life limit is approaching.

v Replace when damage or cracks is detected or life limit is approaching.
vi The battery is to be replaced at given maintenance interval or at battery low alert.
vii Not needed separately if already included in the application.
viii Recommended test interval is within the range 8-48 hours.

4 Maintenance
4.2.3 Expected component life
4.2.3 Expected component life
Expected life depends on usage

The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
Expected component life
Component Expected life Note

Cable harness, normal us- 30000 hours ii
age i
Cable harness, extreme us- 30000 hours ii
age iii
Gearboxes 30000 hours
i Examples of "normal usage" in regard to movement: most material handling applications and limited
use of bending backwards mode of axis 3.
ii Severe chemical or thermal environments, or similar environments, can result in shortened life
expectancy.
iii 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.

4 Maintenance
4.3.1 Cleaning the CRB 1100
4.3 Cleaning activities
4.3.1 Cleaning the CRB 1100
General
To secure high uptime it is important that the CRB 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
CRB 1100.
Note
Always verify the protection type of the robot before cleaning.
WARNING
Turn off all electrical power supplies to the robot before starting the cleaning.
Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Do not point the water jet at connectors, joints, sealings or gaskets.
• Do not use compressed air to clean the robot.
• Do not use solvents that are not approved by ABB to clean the robot.
• Do not remove any covers or other protective devices before cleaning the
robot.
Cleaning methods
This following table defines what cleaning methods are allowed for ABB
manipulators depending on the protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water,
cleaner steam or spray
Standard Yes Yes. With light No No
IP40 cleaning deter-
gent.
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
• Clean the cables if they have a crusty surface, for example from dry release
agents.

4 Maintenance
4.4.1 Inspecting the information labels
4.4 Inspection activities
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on manipulator labels on page 21.
B A A B
C E
Read
Brake release
Rating label
manual
UL Calibration
label label
F
D
G
xx2100000161
A ABB logo, also specifying robot type

B Cobot label
C Instruction label
Brake release
D UL label
E Read manual label, also specifying warning labels
F Rating label, CE label and AbsAcc label
G Calibration label
Required tools and equipment

Visual inspection, no tools are required.

4 Maintenance
Continued
Inspecting, labels
Action Note
1
DANGER
Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the safeguarded space.
2 Inspect the labels, located as shown in the figures.

3 Replace any missing or damaged labels. Article numbers for the labels and
plate set is specified in Spare
parts on page 715.

4 Maintenance
4.4.2 Inspecting the robot cabling
4.4.2 Inspecting the robot cabling

Visual inspection, no tools are required.
Other tools and procedures may be required if the spare part needs to be replaced.
These are specified in the replacement procedure.
Inspection, robot cabling

Use this procedure to inspect the robot cabling.
Action Note
1
DANGER
Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.
2 Visually inspect:
• the control cabling between the robot and
control cabinet
• the cabling to motors 1 and 2.
Look for abrasions, cuts or crush damage.
3 Replace the cabling if wear or damage is detected.

4 Maintenance
4.4.3 Inspecting timing belts
Location of timing belts
Note
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
1
xx1800002457
xx1800002458

4 Maintenance
Continued
Axis Location
3
xx1800002459
xx1800002460

4 Maintenance
Continued
Axis Location
5
xx1800002461
xx1800002462
Equipment Note
Standard toolkit The content is defined in the section Stand-
ard toolkit on page 712.
Other tools and procedures may be required
if the spare part needs to be replaced. These
are specified in the replacement procedure.

4 Maintenance
Continued
Inspecting timing belts

Use this procedure to inspect timing belts.
Action Information
1
DANGER
Turn off all:

to the robot, before entering the robot
working area.
2 Gain access to each timing belt by removing

the cover.
3 Check the timing belts for damage or wear.
4 Check the timing belt pulleys for damage.
5 If any damage or wear is detected, the part
must be replaced!

4 Maintenance
4.5.1 Lubricating the cable package
4.5 Lubricating activities
Location of the cable package

The CRB 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.
Lower cable package Upper cable package
xx1800002465
xx1800002466
Equipment Note
Standard toolkit The content is defined in the section Stand-
ard toolkit on page 712.
Other tools and procedures may be required
if the spare part needs to be replaced. These
are specified in the replacement procedure.
Required consumables
Consumable Article number Note

Grease 3HAC029132-001 FM 222
Lubricating the cable package

Use this procedure to lubricate the cable package.
Action Information
1
DANGER
Turn off all:

to the robot, before entering the robot
working area.

4 Maintenance
Continued
Action Information
2 Gain access to the cable package by remov-
ing the covers.
3 Check the cable package for damage or
wear.
4 If any damage or wear is detected, the part See Replacing the upper cable package
must be replaced! on page 196 and Replacing the lower cable
package on page 239.
5 Apply grease to the cable package, cover
all moving area of the package.
6 Apply grease to the covers that have con-
tacting area with the cable package.

4 Maintenance
4.6.1 Replacing the battery pack
4.6 Replacing/changing activities
Location of the battery pack

The battery pack is located as shown in the figure.
xx1800002463
Note
www.abb.com/myABB.

Battery pack 3HAC044075-001 Battery includes protection cir-
cuits. Only replace with the spe-
cified spare part or an ABB-ap-
proved equivalent.

4 Maintenance
Continued
Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 712.
Calibration tool box, Axis Calibra- 3HAC074119-001 Delivered as a set of calibration
tion tools.
Required if Axis Calibration is the
valid calibration method for the
robot.
The tool box also includes a
unique calibration pin for CRB
1100 to be fitted to the tool flange
during calibration of axis 6.
24 VDC power supply - Used to release the motor brakes.

Cable straps -
Grease 3HAC029132-001 FM 222
Removing the battery pack

Use these procedures to remove the battery pack.
Preparations before removing the battery pack
Action Note
1 Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.
2 Jog all axes to zero position.
xx1800003288

4 Maintenance
Continued
Action Note
3
DANGER
Turn off all:

to the robot, before entering the safeguarded
space.
Disconnecting the SMB connectors
Action Note
1
DANGER
Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit read the safety information in section The
unit is sensitive to ESD on page 48.
3 Remove the SMB cover attachment screws and

carefully open the cover.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
CAUTION
There are cabling attached to the cover. The

cover cannot be removed completely until the
connectors are removed. xx1800002467
4 Disconnect the connectors.

• SMB.P7
• SMB.J1
• SMB.J2
Tip
Take photos of the connector and cable position

before disconnecting them, to have as a reference
when reconnecting.
xx1800002468

4 Maintenance
Continued
Action Note
5 Remove the SMB cover completely from the base.
Action Note
1
DANGER

off.
2

3 Disconnect the battery cable.
xx1800002469
4 Remove the battery pack by cutting the cable

strap.
xx1800002470

4 Maintenance
Continued
Refitting the battery pack

Use these procedures to refit the battery pack.
Action Note
1

2 Secure the battery pack using the cable strap.
xx1800002470
3 Reconnect the battery cable.
xx1800002469
Reconnecting the SMB connectors
Action Note
1


4 Maintenance
Continued
Action Note
2 Reconnect the connectors. Tightening torque: 0.3 Nm
• SMB.P7
• SMB.J1
• SMB.J2
Tip
See the number markings on the connectors for

help to find the corresponding connector.
xx1800002468
3 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.
4 Refit the SMB cover to the base. Screw: M3x8 12.9 Lafre
2C2B/FC6.9 (6 pcs)
Tightening torque: 1.2 Nm
xx1800002467
Concluding procedure
Action Note
1 Recalibrate the robot. Calibration is detailed in section
2
DANGER
Make sure all safety requirements are met when

performing the first test run. See Test run after
installation, maintenance, or repair on page 165.

5 Repair
5.1 Introduction
5 Repair
5.1 Introduction
Structure of this chapter

This chapter describes repair activities for the CRB 1100. Each procedure contains
the information required to perform the activity, for example spare parts numbers,
required special tools, and materials.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Report replaced units
Note
When replacing a part on the CRB 1100, report to your local ABB the serial
number, the article number, and the revision of both the replaced unit and the
replacement unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 17 before commencing any
service work.
Note
If the CRB 1100 is connected to power, always make sure that the CRB 1100 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.

5 Repair
5.2.1 Mounting instructions for sealings
5.2 General procedures
General
This section describes how to mount different types of sealings.
Equipment

Grease 3HAC031695-001 Harmonic Grease 4B No.2
Used to lubricate the seals.
Rotating sealings
The following procedures describe how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:

• Protect the sealing during transport and mounting, especially the main lip
on radial sealings.
• Keep the sealing in its original wrappings or protect it well before actual
mounting.
• The fitting of sealings and gears must be carried out on clean workbenches.
• Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
• Do not lubricate a static side of a sealing with grease, since this may result
in movement of the sealing during operation.
The only exception for lubrication of static sides of a sealing, is to use P-80
rubber lubrication gel against certain aluminium surfaces. If usage of P-80
is relevant, it is stated in the repair procedures.
Radial sealings
A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only
one side of the sealing is static with a metal insert.
xx2300000433

5 Repair
Continued
Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 190.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip
Note
Ensure that no grease is ap-

plied to the red marked surface.

5 Repair
Continued
Action Note
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.
xx2000000072
A Gap
Flange sealings and static sealings

The following procedure describes how to fit flange sealings and static sealings.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface.
4 Tighten the screws evenly when fastening the flange joint.
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.

5 Repair
Continued
Action Note
3 Check the o-ring grooves and mating surfaces.
They should be free of pores, contamination
and obvious scratches/damage.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.

5 Repair
5.2.2 Cut the paint or surface on the robot before replacing parts
5.2.2 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx2300000950
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

5 Repair
5.3 Cable harness
5.3 Cable harness
General
The CRB 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.
The main cable package includes the cabling for all the six motors. Optional air
hoses, CP/CS cabling and Ethernet cabling can also be included.
As standard feature, the connector interface is located at the rear of the base. The
interface can also be bottom mounted, as an option. This section describes both
configurations.

5 Repair
5.3.1 Replacing the upper cable package
Location of the upper cable package

The upper cable package is located as shown in the figure.
xx1800002466
Note
www.abb.com/myABB.

Upper cable harness (CP/CS and 3HAC060419-003 Used with CRB 1100-4/0.475.
air hose, with Ethernet)
Extension upper cable harness 3HAC060416-003 Used with CRB 1100-4/0.58.
(CP/CS and air hose, with Ethernet)
Process hub with lamp unit (CP/CS 3HAC077335-001
and air hose, with Ethernet)
Multi-color lamp unit (14 mm) 3HAC076495-001
Lamp unit cover 3HAC075972-001
Motor with flange, axis 2 3HAC083588-001 .
Timing belt, axis 2 3HAC061935-001

5 Repair
Continued

Motor with flange, axis 3 3HAC083587-001
Swing cover 3HAC069051-001
Swing support cover 3HAC069052-001
Wrist cover 3HAC069061-001
Housing cover 3HAC069054-001
Lower arm cover 3HAC069057-001
Lower arm support cover 3HAC069059-001
Cooling pad for axis-1 and -2 mo- 3HAC071020-001 Cooling pads are wear parts. One
tors cooling pad sheet contains 6
pieces of small pad.
Replace if damaged with one
piece each time.
tors cooling pad sheet includes 10
piece each time.
Washer 3HAC063985-001 9x4.3x1, Steel
Washer 3HAC064765-001 7x3.2x1.5, Steel
Cable protector, axis 3 3HAC088722-001 Replace if damaged

tion tools.
robot.
Sonic tension meter - Used for measuring the timing
belt tension.
Dynamometer - Used for measuring the timing
belt tension.
M3x25 eye bolt - Included in the special toolkit
3HAC071022-001.

5 Repair
Continued

J5.C2 connector assembly tool - Included in the special toolkit
3HAC071022-001.
Used to remove and refit the
J5.C2 connector, if the Ethernet
cabling is equipped.

Cable straps -
Grease 3HAC029132-001 FM 222
Locking liquid - Loctite 2400 (or equivalent Loctite
243)
Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot. Note
• Reference calibration. External cable
packages (DressPack) and tools can Calibrating axis 6 always requires tools to
stay fitted on the robot. be removed from the mounting flange (also
• Fine calibration. All external cable for reference calibration) since the mount-
packages (DressPack) and tools ing flange is used for installation of the
must be removed from the robot. calibration tool.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 662.
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removing the upper cable package

Use these procedures to remove the upper cable package.
Preparations before removing the upper cable package
Action Note
procedure.

5 Repair
Continued
Action Note
2 Jog the robot to the specified position:
• Axis 1: 0°
• Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB
1100-4/0.58)
• Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB
1100-4/0.58)
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: No significance.
xx1800003289
3
DANGER
Turn off all:

space.
Removing the axis-2 motor
Action Note
1
DANGER

off.
2
CAUTION
Removing motors will release axes. This means

the axes can fall down.
Make sure axes are well supported before remov-
ing motors.
3 Remove the swing support cover.
xx1800002488

5 Repair
Continued
Action Note
4 Remove the connector plate.
CAUTION
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
5 Disconnect the connector.

• J2.FB2
Tip

when reconnecting.
xx1800002490
6 Snap loose and remove the female head of the

connector from the connector plate.
xx1800002491
7 Remove the swing cover.
xx1800002492

5 Repair
Continued
Action Note
• MP2
Tip

when reconnecting.
xx1800002495
9 Loosen the screws and move the motor slightly

to slacken the timing belt.
xx1800002493
10 Remove the screws and washers.
xx1800002494
11 Carefully lift out the motor. Cooling pad location
CAUTION
A cooling pad is attached to the motor, which may

stick to the casting. Always use a plastic sheet
with caution to remove the pad from the casting.
Pay attention not to scratch the casting or damage
the pad.
CAUTION
Be aware of the motor cabling. The motor cannot

be removed completely until the connector is xx1800003603
disconnected, as shown in following step.

5 Repair
Continued
Action Note
12 Remove the timing belt from its groove on the
motor.
xx1800002496
Disconnecting the connectors at the division point
Action Note
1
DANGER

off.

• J2.FB3,4,5,6
• J2.MP3,4,5/6
Tip

when reconnecting.
xx1800002497

connectors from the connector plate.
xx1800002498

5 Repair
Continued
Separating the cable package from the swing
Action Note
1
DANGER

off.
2 Remove the cable bracket.
xx1800002499
Disconnecting the air hoses, CP/CS cabling and Ethernet cabling (if equipped)
Action Note
1
DANGER

off.
2 Disconnect the air hoses from the Y-shaped con-

nectors.
xx1800002500

5 Repair
Continued
Action Note
• J2.C1
• J2.C2
Tip

when reconnecting.
Tip
xx1800002501
The connector clip has to be pressed (1) and
pushed forward (2) to separate the J2.C2 (for
Ethernet cabling).
xx1800002943
Removing the process hub
Action Note
1
DANGER

off.
2 Remove the screws and carefully open the cover.
CAUTION
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.
xx2000002219

5 Repair
Continued
Action Note
3 Disconnect the air hoses.
xx1800002945
4 Carefully pull out lamp unit connector behind the

air hose connectors and disconnect the connector
J5.UL.
xx1800002946
5 For robots with CP/CS cabling

Disconnect the connector.
• J5.C1
xx2100000293
6 For robots with Ethernet cabling J5.C2 connector assembly tool: -

Disconnect the connector J5.C2 using the tool.
xx1800002948

5 Repair
Continued
Removing the lamp unit

Notice that the procedure is valid only when the lamp unit needs a replacement.
Action Note
1 Remove the lamp unit cover.
xx2000002220
2 Remove the lamp unit.
xx2000002221
Removing the wrist covers
Action Note
1
DANGER

off.
2 Remove the wrist covers from both sides.
xx1800002949

5 Repair
Continued
Disconnecting the axis-5 motor connectors
Action Note
1
DANGER

off.
2 Access the connector FB5 from the process hub

and disconnect the connector.
xx1800002950

• MP5
xx1800002993
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
• MP6
• FB6
xx1800002994
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

xx1800002995

5 Repair
Continued
Action Note
xx1800002996
5 Carefully lift out the motor.

motor.
xx1800002997
Loosening the cable package from axis-4 gearbox
Action Note
1
DANGER

off.
2 Valid for CRB 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

5 Repair
Continued
Action Note
3 Remove the plug screw and washer on the ex-
tender unit to access the cable package locking
screw on the axis-4 gearbox and then loosen the
locking screw.
xx1800003000
xx1800003001
Separating the upper cable harness from the axis-2 gearbox
Action Note
1
DANGER

off.
xx1800003002

5 Repair
Continued
Action Note
1
DANGER

off.
2 Remove the lower arm support cover.
xx1800003003
CAUTION

move from the plate, as shown in following step.
xx1800003004
4 Slide the connectors out of the connector plate

and disconnect the connectors.
• FB3
• MP3
Tip

when reconnecting.
xx1800003005

5 Repair
Continued
Action Note
xx1800003006
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
3 Remove the lower arm cover.
xx1800003007

5 Repair
Continued
Action Note
xx1800003008
xx1800003009
CAUTION

the pad.
xx1800003604

5 Repair
Continued
Action Note
motor.
xx1800003010
Action Note
1
DANGER

off.
2 Remove the housing cover.
xx1800003011
3 Disconnect the motor connectors.

• FB4
• MP4
xx1800003012

5 Repair
Continued
Separating the upper cable package from the housing
Action Note
1
DANGER

off.
xx1800003013
xx1800003014
Pulling out the upper cable harness
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2 Pull out the upper cable harness from the robot
in the direction shown in the figure.
xx1800003015
Refitting the upper cable package

Use these procedures to refit the upper cable package.
Refitting the upper cable harness through the axis-4 gearbox
Action Note
1 Check the cable protector, axis 4. Cable protector, axis 4:
Replace if damaged. 3HAC088723-001
xx2300001789

5 Repair
Continued
Action Note
2 Insert the cable package in the housing and Cable protection tube orientation:
through the axis-4 gearbox. use the notch (A) on the cable pro-
tection tube as a reference when
inserting the cable package, which
Tip should be at the opposite direction
to the locking screw hole (B) on the
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

5 Repair
Continued
Securing the upper cable package to the axis-4 gearbox
Action Note
1 Make sure that: Holes to be aligned are shown in
• The hole on the cable protection tube is the following figure.
aligned with the locking screw hole on the
gearbox.
• The cable protection tube surface is com-
pletely parallel with the pulley cover at one
side and with the flange at the other side.
xx1800003018
Surfaces to be paralleled are

shown in the following figures.
xx1800003019
xx1800003020

5 Repair
Continued
Action Note
2 Apply a little Loctite 243 to the locking screw and Screw: M3x8 (1 pcs)
refit the locking screw. Tightening torque: 0.4 Nm
Valid for CRB 1100-4/0.475
Note
Make sure the locking screw header is parallel

with flange surface.
Note
If there is locking liquid residues on the screw or

screw hole, please clean it before refitting.
Remove residual locking liquid after refitting.
xx1800003031
xx1800003001
3 Refit the plug screw and washer on the extender Plug screw: 3HAC064146-001
unit. Tightening torque: 2 Nm
xx1800003000

5 Repair
Continued
Guiding the upper cable package down to the swing
Action Note
xx2300001788
2 Guide the upper cable package to go though from

the housing, though the lower arm, down to the
swing.
When inserting the cable package, leave the axis-
4 motor connectors in the housing and the axis-3
motor connectors in the lower arm.
Tip
Wrap the connectors with the masking tape.
Tip
It is possible to remove the lower arm support and

swing support for easy routing of the cable pack-
age. Remember to refit the lower arm support and xx1800003016
swing support after the cable package is inserted
to place.

5 Repair
Continued
Securing the upper cable package to the housing
Action Note
1 Refit the cable bracket. Screw: M3x8 12.9 Lafre
2C2B/FC6.9 (2 pcs)
xx1800003013
Screw: M2.5x6 12.9 Lafre

2C2B/FC6.9 (2 pcs)
xx1800003014
CAUTION


5 Repair
Continued
Reconnecting the axis-4 motor connectors
Action Note
1 Check the cabling status.
Make sure the cabling is in vertical state and is
not twisted.
xx1800003618
2 Reconnect the connectors.

• FB4
• MP4
Tip

xx1800003012
Refitting the axis-3 motor
Action Note
1 Check that:
• all assembly surfaces are clean and without
damages
• the motor is clean and undamaged.
2 Check the cooling pad. Cooling pad for axis-3 and -4 mo-
Replace if damaged. tors: 3HAC071021-001
xx1800003604

5 Repair
Continued
Action Note
3 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
4 Refit the screws and washers. Screw: M4x12 12.9 Lafre

2C2B/FC6.9 (3 pcs)
Note Washer, 3HAC063985-001 (3 pcs)
Do not tighten the screws yet.
xx1800003009
5 Install the timing belt to the pulleys and verify that

the belt runs correctly in the grooves of the pul-
leys.
xx1800003022

5 Repair
Continued
Action Note
6 Install an M4x25 or longer adjustment screw to
the motor.
Note
Do not insert the entire screw to the hole.
xx1900000009
7 Use a handheld dynamometer hooking to the

screw and pull the dynamometer to tension the
timing belt.
xx1900000028
8 Tighten the motor screws. Tightening torque: 3 Nm
xx1800003008

5 Repair
Continued
Action Note
9 Use a sonic tension meter to measure the timing Used belt: 102-109 Hz
belt tension. New belt:122-128 Hz
If the timing belt tension does not meet the require-
ment, loosen the motor screws and readjust.
10 Remove the adjustment screw from the motor.
xx1900000009
Action Note
1 Slide the connectors into the connector plate and
reconnect the connectors.
• FB3
• MP3
Tip

xx1800003005
CAUTION


5 Repair
Continued
Action Note
3 Refit the cable bracket. Screw: M2.5x6 12.9 Lafre
2C2B/FC6.9 (2 pcs)
xx1800003006
4 Refit the connector plate. Screw: M3x12 12.9 Lafre

2C2B/FC6.9 (2 pcs)
xx1800003004
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003002

5 Repair
Continued
Action Note
1 Check that:
damages
nector.
Tip
Leave the connectors FB5 and FB6 accessible

from the process hub and the connectors MP5
and MP6 accessible from wrist side.
xx1800003023

2C2B/FC6.9 (3 pcs)
Note
xx1800002996

leys.
xx1800003024

5 Repair
Continued
Action Note
the motor.
Note
xx1900000007

timing belt.
xx1900000026
7 Tighten the motor screws. Tightening torque: 1.4 Nm
xx1800002995
8 Use a sonic tension meter to measure the timing Used belt: 81.3-86.9 Hz
belt tension. New belt:97.2-101 Hz
xx1900000007

5 Repair
Continued
Action Note
• FB5
• MP5
Tip

xx1800003025
CAUTION

3 Insert the cabling and connectors into the wrist.
Action Note
• FB6
• MP6
Tip

xx1800002994
CAUTION


5 Repair
Continued
Refitting the lamp unit

Notice that the procedure is valid only when the lamp unit needs a replacement.
Action Note
1 Refit the lamp unit. Multi-color lamp unit (14 mm):
3HAC076495-001
xx2000002221
2 Refit the lamp unit cover. Lamp unit cover: 3HAC075972-001

Screw: M2x8 12.9 Gleitmo 605 (3
pcs)
xx2000002220
Refitting the process hub
Action Note
1 Reconnect the lamp unit connector J5.UL and
place the connector behind the air hose connect-
ors.
xx1800002946

5 Repair
Continued
Action Note
2 Reconnect the air hoses in a cross pattern.
Tip
See the number markings on the air hoses for

help to find the corresponding air hoses.
The air hoses with the same number connect to
the same Y-shaped connector.
xx1800002945

Reconnect the connector.
• J5.C1
xx2100000293
4 For robots with Ethernet cabling J5.C2 connector assembly tool, in-
Reconnect the connector J5.C2 using the tool. cluded in the special toolkit
3HAC071022-001
xx1800002948
CAUTION


5 Repair
Continued
Action Note
6 Refit the cover. Screw: M3x8 12.9 Lafre
2C2B/FC6.9 (4 pcs)
xx2000002219
Reconnecting the air hoses, CP/CS cabling and Ethernet cabling (if equipped)
Action Note
1 Reconnect the air hoses in a cross pattern to the
Y-shaped connectors.
Tip

xx1800002500

• J2.C1
• J2.C2
Tip

xx1800002501

5 Repair
Continued
Securing the cable package to the swing
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002499
Action Note
1 Check that:
damages
Replace if damaged, as shown in the following tors: 3HAC071020-001
step.
xx1800003603

5 Repair
Continued
Action Note
3 Remove the screws. Screw: M3x5 12.9 Lafre
Replace with a new cooling pad and then refit the 2C2B/FC6.9 (2 pcs)
screws. Tightening torque: 1.2 Nm
xx1800003026
4 Orient the motor correctly and fit it into the swing. Motor orientation: orient the motor
according to the figure below, in
Tip nector.
Bend the motor signal cable back towards the

swing support.
xx1800003027

2C2B/FC6.9 (3 pcs)
xx1800002494

5 Repair
Continued
Action Note
leys.
xx1800003028

the motor.
Note
xx1900000010

timing belt.
xx1900000029

5 Repair
Continued
Action Note
xx1800002493
xx1900000010
12 Reconnect the connector.

• MP2
Tip

xx1800002495

5 Repair
Continued
Reconnecting the connectors at the division point
Action Note
1 Insert the female header of the connectors to the
connector plate.
xx1800003029

• J2.FB2,3,4,5,6
• J2.MP3,4,5/6
Tip

xx1800003030
CAUTION


2C2B/FC6.9 (2 pcs)
xx1800002489

5 Repair
Continued
Refitting the covers
Action Note
1 Apply grease to the cable package, cover all
moving area of the package.
2 Apply grease to the covers that have contacting
area with the cable package.
3 Refit the covers. Screw: M3x8 12.9 Lafre
• Wrist covers 2C2B/FC6.9
• Housing cover Tightening torque: 1.2 Nm
• Lower arm cover
• Lower arm support cover
• Swing cover
• Swing support cover
xx1800003606
Action Note
2
DANGER


5 Repair
5.3.2 Replacing the lower cable package
Location of the lower cable package

The lower cable package is located as shown in the figure.
xx1800002465
Note
www.abb.com/myABB.

Lower cable harness (CP/CS and 3HAC075523-001
Base bottom cover 3HAC060463-001 Standard configuration, used for
robots with rear connector inter-
face.
Base rear cover 3HAC070312-001 Used for robots with bottom con-
nector interface.
Base adapter 3HAC070313-001 Used for robots with bottom con-
nector interface.

5 Repair
Continued

SMB cover 3HAC069060-001
piece each time.

tion tools.
robot.
belt tension.
belt tension.
brake release button assembly tool - Included in the special toolkit
3HAC071022-001.
brake release button.

Cable straps -
Grease 3HAC029132-001 FM 222
243)

5 Repair
Continued

Action Note
calibration:
Removing the lower cable package

Use these procedures to remove the lower cable package.
Preparations before removing the lower cable package
Action Note
procedure.
xx1800003288

5 Repair
Continued
Action Note
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
xx1800002488
CAUTION

xx1800002489

5 Repair
Continued
Action Note
• J2.FB2
Tip

when reconnecting.
xx1800002490

xx1800002491
xx1800002492

• MP2
Tip

when reconnecting.
xx1800002495

5 Repair
Continued
Action Note
xx1800002493
xx1800002494
CAUTION

the pad.
CAUTION


motor.
xx1800002496

5 Repair
Continued
Action Note
1
DANGER

off.
2 Access the cable package locking screw on the

axis-1 gearbox from the swing and then loosen
the locking screw.
xx1800003032
3 Remove the locking screw.
Action Note
1
DANGER

off.

• J2.FB3,4,5,6
• J2.MP3,4,5/6
Tip

when reconnecting.
xx1800002497

5 Repair
Continued
Action Note
xx1800002498
Action Note
1
DANGER

off.
xx1800002499
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
nectors.
xx1800002500

• J2.C1
• J2.C2
Tip

when reconnecting.
Tip
xx1800002501
Ethernet cabling).
xx1800002943
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2


CAUTION

CAUTION


• SMB.P7
• SMB.J1
• SMB.J2
Tip

when reconnecting.
xx1800002468
Putting the robot on its side
Action Note
1
DANGER

off.
2
CAUTION
The CRB 1100 robot weighs 21.1 kg and can be

lifted by one person.

5 Repair
Continued
Action Note
3
WARNING
The robot is likely to be mechanically unstable if

not secured to the foundation.
4 Loosen the robot from the foundation by removing

the foundation attachment screws and put the
robot on its side.
xx1800003033
Opening the connector interface plate
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2 Remove the connector interface plate attachment Valid for cabling with rear inter-
screws and carefully open the plate. face
CAUTION

connectors are removed.
xx1800003034
Valid for cabling with bottom inter-

face (option 3309-1)
xx1800003055
3 Valid for cabling with bottom interface (option

3309-1)
Remove the base adapter.
xx1800003056

5 Repair
Continued
Removing the brake release button

Notice that the procedure differs depending on if the connector interface is located
either at the rear or at the bottom of the base.
Action Note
1
DANGER

off.
2 Valid for cabling with rear interface

Remove the base bottom cover.
xx1800003035

3309-1)
Remove the base rear cover.
xx1800003057
4 Disconnect the earth cable.
xx1800003036

5 Repair
Continued
Action Note
xx1800003037

• J1M.BR
Tip

when reconnecting.
xx1800003038
7 Remove the female header of the J1M.BR connect-

or from the connector plate.
xx1800003039

5 Repair
Continued
Action Note
8 Remove the brake release button from the base brake release button assembly
using the tool. tool, included in the special toolkit
3HAC071022-001
xx1800003040
Disconnecting axis-1 motor connectors
Action Note
1
DANGER

off.

• FB1
• MP1
Tip

when reconnecting.
xx1800003041
Separating the cable package from the base
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800003042
Separating the cable package from the axis-1 gearbox
Action Note
1
DANGER

off.
2 Remove the pulley cover.
xx1800003043
Pulling out the cable package
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2 Pull out the lower cable package from the axis-1
gearbox.
xx1800003044
3 Pull out the lower cable package from the base.
xx1800003045
4 Remove the pulley cover from the lower cable

package.
xx1800003046

5 Repair
Continued
Refitting the lower cable package

Use these procedures to refit the lower cable package.
Refitting the brake release button
Action Note
1 Refit the brake release button. brake release button assembly
tool, included in the special toolkit
Note 3HAC071022-001
Do not reconnect the connector yet.

Do not tighten the button yet.
xx1800003040
Refitting the lower cable package through the axis-1 gearbox

Action Note
1 Refit the pulley cover to the lower cable package.
xx1800003046

5 Repair
Continued
Action Note
Insert the cable package in the base and up
through the axis-1 gearbox, through the rear.
Tip
CAUTION

xx1800003047
Cable protection tube orientation:
use the encircled notch on the
cable protection tube as a refer-
ence when inserting the cable
package, which should be at the
opposite direction to the locking
screw hole on the gearbox.
xx1800003048

5 Repair
Continued
Action Note
3309-1)
through the axis-1 gearbox, through the bottom.
Tip
CAUTION

xx1800003060
xx1800003048

5 Repair
Continued
Securing the lower cable package to the axis-1 gearbox
Action Note
1 Make sure that:
• The hole on the cable protection tube is
gearbox.
xx1800003063
xx1800003049
xx1800003050

5 Repair
Continued
Action Note
Note

Note

xx1800003032
Refitting the pulley cover
Action Note
1 Refit the puller cover. Screw: M3x8 12.9 Lafre
2C2B/FC6.9 (3 pcs)
xx1800003043
Action Note
1


5 Repair
Continued
Action Note
• SMB.P7
• SMB.J1
• SMB.J2
Tip

xx1800002468
CAUTION

2C2B/FC6.9 (6 pcs)
xx1800002467
Refitting the connector interface plate
Action Note
CAUTION


5 Repair
Continued
Action Note
2 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
3 Refit the connector interface plate to the base. Screw: M3x30 12.9 Lafre
2C2B/FC6.9 (6 pcs)
Valid for cabling with rear inter-
face
xx1800003034

xx1800003055

5 Repair
Continued
Securing the lower cable package to the base
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003042
Securing the brake release button
Action Note
1 Tighten the brake release button using the tool. brake release button assembly
3HAC071022-001
xx1800003040

5 Repair
Continued
Reconnecting the brake release cabling and axis-1 motor connectors
Action Note
• J1M.BR
• MP1
• FB1
Tip

xx1800003054
2 Reconnect the floor cable together with the con- Screw: M3x8 12.9 Lafre
nector plate. 2C2B/FC6.9 (2 pcs)
xx1800003037
xx1800003036

5 Repair
Continued
Refitting the base cover

Action Note
CAUTION

4 Valid for cabling with rear interface Screw: M3x8 Steel 8.8-A2F (7 pcs)
Refit the bottom cover. Tightening torque: 1.2 Nm
xx1800003035
5 Refit the rear cover. Screw: M3x8 12.9 Lafre

2C2B/FC6.9 (6 pcs)
xx1800003057

5 Repair
Continued
Action Note
1
CAUTION

2 Raise the robot to standing and secure to the Attachment screws: M12x25 (robot
foundation with the attachment screws and installation directly on foundation),
washers. quality: 8.8.
Washers: 4 pcs, 24 x 13 x 2.5.
Tightening Torque: 50 Nm±5 Nm.
Action Note
Tip

xx1800002500

• J2.C1
• J2.C2
Tip

xx1800002501

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002499
Action Note
1 Check that:
damages
step.
xx1800003603

5 Repair
Continued
Action Note
xx1800003026
Tip nector.

swing support.
xx1800003027

2C2B/FC6.9 (3 pcs)
xx1800002494

5 Repair
Continued
Action Note
leys.
xx1800003028

the motor.
Note
xx1900000010

timing belt.
xx1900000029

5 Repair
Continued
Action Note
xx1800002493
xx1900000010

• MP2
Tip

xx1800002495

5 Repair
Continued
Action Note
connector plate.
xx1800003029

• J2.FB2,3,4,5,6
• J2.MP3,4,5/6
Tip

xx1800003030
CAUTION


2C2B/FC6.9 (2 pcs)
xx1800002489

5 Repair
Continued
Refitting the swing covers
Action Note
• Swing cover 2C2B/FC6.9
• Swing support cover Tightening torque: 1.2 Nm
xx1800003607
Action Note
2
DANGER


5 Repair
5.3.3 Replacing the SMB unit
Location of the SMB unit

The SMB unit is located as shown in the figure.
xx1800002464
Note
www.abb.com/myABB.

Serial measurement unit 3HAC063968-001
Battery pack 3HAC044075-001 Battery includes protection cir-
cuits. Only replace with the spe-
cified spare part or an ABB-ap-
proved equivalent.

5 Repair
Continued

tion tools.
robot.
Required consumables and wear parts

Cable straps -
Grease 3HAC029132-001 FM 222
243)

Action Note
calibration:

5 Repair
Continued
Removing the SMB unit

Use these procedures to remove the SMB unit.
Preparations before removing the SMB unit
Action Note
procedure.
2 Jog the robot to the synchronization position.
xx1800003288
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
2


5 Repair
Continued
Action Note
CAUTION

CAUTION


• SMB.P7
• SMB.J1
• SMB.J2
Tip

when reconnecting.
xx1800002468
Action Note
1
DANGER

off.
2


5 Repair
Continued
Action Note
3 Disconnect the battery cable.
xx1800002469
4 Remove the battery pack by cutting the cable

strap.
xx1800002470
Removing the SMB unit
Action Note
1
DANGER

off.
2


5 Repair
Continued
Action Note
3 Remove the screws.
xx1800002471
Refitting the SMB unit

Use these procedures to refit the SMB unit.
Refitting the SMB unit
Action Note
1

2 Refit the screws. Screw: M3x5 12.9 Lafre

2C2B/FC6.9 (4 pcs)
xx1800002471
Action Note
1


5 Repair
Continued
Action Note
2 Secure the battery pack using the cable strap.
xx1800002470
3 Reconnect the battery cable.
xx1800002469
Action Note
1


• SMB.P7
• SMB.J1
• SMB.J2
Tip

xx1800002468

5 Repair
Continued
Action Note
CAUTION

2C2B/FC6.9 (6 pcs)
xx1800002467
Action Note
2
DANGER


5 Repair
5.4.1 Replacing the base
5.4 Swing and base
Location of the base

The base is located as shown in the figure.
xx1800002472
Note
www.abb.com/myABB.

Base 3HAC069048-001

5 Repair
Continued

face.
nector interface.
nector interface.
piece each time.

tion tools.
robot.
belt tension.
belt tension.
3HAC071022-001.

Cable straps -
Grease 3HAC029132-001 FM 222
243)

5 Repair
Continued

Action Note
calibration:
Removing the base

Use these procedures to remove the base.
Preparations before removing the base
Action Note
procedure.
xx1800003288

5 Repair
Continued
Action Note
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
xx1800002488
CAUTION

xx1800002489

5 Repair
Continued
Action Note
• J2.FB2
Tip

when reconnecting.
xx1800002490

xx1800002491
xx1800002492

• MP2
Tip

when reconnecting.
xx1800002495

5 Repair
Continued
Action Note
xx1800002493
xx1800002494
CAUTION

the pad.
CAUTION


motor.
xx1800002496

5 Repair
Continued
Action Note
1
DANGER

off.

the locking screw.
xx1800003032
Action Note
1
DANGER

off.

• J2.FB3,4,5,6
• J2.MP3,4,5/6
Tip

when reconnecting.
xx1800002497

5 Repair
Continued
Action Note
xx1800002498
Action Note
1
DANGER

off.
xx1800002499
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
nectors.
xx1800002500

• J2.C1
• J2.C2
Tip

when reconnecting.
Tip
xx1800002501
Ethernet cabling).
xx1800002943
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2
CAUTION

3
WARNING


robot on its side.
xx1800003033
Action Note
1
DANGER

off.
2


CAUTION

CAUTION


5 Repair
Continued
Action Note
• SMB.P7
• SMB.J1
• SMB.J2
Tip

when reconnecting.
xx1800002468
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
CAUTION

xx1800003034

xx1800003055

3309-1)
xx1800003056

5 Repair
Continued

Action Note
1
DANGER

off.

xx1800003035

3309-1)
xx1800003057
xx1800003036

5 Repair
Continued
Action Note
xx1800003037

• J1M.BR
Tip

when reconnecting.
xx1800003038

xx1800003039

5 Repair
Continued
Action Note
3HAC071022-001
xx1800003040
Action Note
1
DANGER

off.

• FB1
• MP1
Tip

when reconnecting.
xx1800003041
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800003042
Action Note
1
DANGER

off.
xx1800003043
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
gearbox.
xx1800003044
xx1800003045

package.
xx1800003046
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2
CAUTION

ing motors.

xx1800003064
xx1800003065
CAUTION

the pad.
xx1800003602

5 Repair
Continued
Action Note
motor.
xx1800003066
Removing the axis-1 timing belt
Action Note
1
DANGER

off.
2
CAUTION
Loosening timing belts will release axes. This

means the axes can fall down.
Make sure axes are well supported before
loosening timing belts.

gearbox.
xx1800003067
Separating the base from the swing
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
Tip
Three screw holes have no screws fitted in.

Take photos of the screw and washer position
before removing them, to have as a reference
when refitting.
xx1800003069
xx1800003068
3 Separate the base from the swing.
CAUTION
The axis-1 mechanical stop is accessible now.

Put it aside for later refitting.
xx1800003070
xx1800003071

5 Repair
Continued
Refitting the base

Use these procedures to refit the base.
Placing the axis-1 mechanical stop
Action Note
1 Check the axis-1 mechanical stop. Mechanical stop, axis 1:
2 Put the axis-1 mechanical stop in place in the

swing.
Note
The mechanical stop can be placed in any place

except the block (A) on the swing. Make sure the
mechanical stop step pointed in the figure is fa-
cing the swing when putting.
xx1800003071
xx1800003619

5 Repair
Continued
Refitting the base to the swing
Action Note
1 Refit the base to the swing. Screw: M4x16 12.9 Lafre
2C2B/FC6.9 (13 pcs)
Note Tightening torque: 4.4 Nm
Pay attention to the screw and washer location.
xx1800003069
xx1800003068
Action Note
Note 3HAC071022-001

xx1800003040
Action Note
1 Check that:
damages

5 Repair
Continued
Action Note
xx1800003602
3 Install the timing belt to the motor pulley and

verify that the belt runs correctly in the groove of
the pulley.
xx1800003085
4 Orient the motor correctly and fit it into the base. Motor orientation: orient the motor
At the same time, install the timing belt to the according to the figure below, in
gearbox pulley and verify that the belt runs cor- regard to the encircled motor con-
rectly in the groove of the pulley. nector.
xx1800003072

5 Repair
Continued
Action Note
2C2B/FC6.9 (3 pcs)
xx1800003065
Adjusting the axis-1 timing belt tension
Action Note
motor.
xx1900000040
2 Pull the dynamometer to make the tension falling Used belt: 58.24-63.56 N
in the allowed force range. New belt:83.2-90.8 N
Note
During the measurement, make sure that all inter-

ferences that may affect the force are removed.
Pay attention to the force application direction.
xx1900000041
3 Secure the motor with the screws. Tightening torque: 3 Nm

5 Repair
Continued
Action Note
3HAC071022-001
xx1800003040

Action Note
xx1800003046

5 Repair
Continued
Action Note
Tip
CAUTION

xx1800003047
xx1800003048

5 Repair
Continued
Action Note
3309-1)
Tip
CAUTION

xx1800003060
xx1800003048

5 Repair
Continued
Action Note
1 Make sure that:
gearbox.
xx1800003063
xx1800003049
xx1800003050

5 Repair
Continued
Action Note
Note

Note

xx1800003032
Action Note
2C2B/FC6.9 (3 pcs)
xx1800003043
Action Note
1


5 Repair
Continued
Action Note
• SMB.P7
• SMB.J1
• SMB.J2
Tip

xx1800002468
CAUTION

2C2B/FC6.9 (6 pcs)
xx1800002467

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003042
Action Note
• J1M.BR
• MP1
• FB1
Tip

xx1800003054

5 Repair
Continued
Action Note
xx1800003037
xx1800003036

Action Note
CAUTION


5 Repair
Continued
Action Note
xx1800003035

2C2B/FC6.9 (6 pcs)
xx1800003057
Action Note
CAUTION


5 Repair
Continued
Action Note
xx1800003056
2C2B/FC6.9 (6 pcs)
face
xx1800003034

xx1800003055

5 Repair
Continued
Action Note
1
CAUTION

Action Note
Tip

xx1800002500

• J2.C1
• J2.C2
Tip

xx1800002501

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002499
Action Note
1 Check that:
damages
step.
xx1800003603

5 Repair
Continued
Action Note
xx1800003026
Tip nector.

swing support.
xx1800003027

2C2B/FC6.9 (3 pcs)
xx1800002494

5 Repair
Continued
Action Note
leys.
xx1800003028

the motor.
Note
xx1900000010

timing belt.
xx1900000029

5 Repair
Continued
Action Note
xx1800002493
xx1900000010

• MP2
Tip

xx1800002495

5 Repair
Continued
Action Note
connector plate.
xx1800003029

• J2.FB2,3,4,5,6
• J2.MP3,4,5/6
Tip

xx1800003030
CAUTION


2C2B/FC6.9 (2 pcs)
xx1800002489

5 Repair
Continued
Action Note
xx1800003607
Action Note
2
DANGER


5 Repair
5.4.2 Replacing the swing
Location of the swing

The swing is located as shown in the figure.
xx1800002473
Note
www.abb.com/myABB.

Swing 3HAC069050-001
Swing support 3HAC069039-001
Base 3HAC069048-001
Gear unit with pulley, axis 1 3HAC069062-001

5 Repair
Continued

face.
nector interface.
nector interface.
piece each time.

tion tools.
robot.
belt tension.
belt tension.
3HAC071022-001.

Cable straps -

5 Repair
Continued

Grease 3HAC029132-001 FM 222
Grease - Castrol Molub. Alloy 777-1 NG
Used to lubricate bearings on the
swing support and lower arm
support.
243)
Sealing compound 3HAC026759-002 Sikaflex 521 FC

Action Note
calibration:
Removing the swing

Use these procedures to remove the swing.
Preparations before removing the swing
Action Note
procedure.

5 Repair
Continued
Action Note
xx1800003288
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
xx1800002488

5 Repair
Continued
Action Note
CAUTION

xx1800002489

• J2.FB2
Tip

when reconnecting.
xx1800002490

xx1800002491
xx1800002492

5 Repair
Continued
Action Note
• MP2
Tip

when reconnecting.
xx1800002495

xx1800002493
xx1800002494
CAUTION

the pad.
CAUTION


5 Repair
Continued
Action Note
motor.
xx1800002496
Action Note
1
DANGER

off.

the locking screw.
xx1800003032
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
• J2.FB3,4,5,6
• J2.MP3,4,5/6
Tip

when reconnecting.
xx1800002497

xx1800002498
Action Note
1
DANGER

off.
xx1800002499

5 Repair
Continued
Action Note
1
DANGER

off.

nectors.
xx1800002500

• J2.C1
• J2.C2
Tip

when reconnecting.
Tip
xx1800002501
Ethernet cabling).
xx1800002943

5 Repair
Continued
Action Note
1
DANGER

off.
2
CAUTION

3
WARNING


robot on its side.
xx1800003033
Action Note
1
DANGER

off.
2


5 Repair
Continued
Action Note
CAUTION

CAUTION


• SMB.P7
• SMB.J1
• SMB.J2
Tip

when reconnecting.
xx1800002468
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
CAUTION

xx1800003034

xx1800003055

3309-1)
xx1800003056

5 Repair
Continued

Action Note
1
DANGER

off.

xx1800003035

3309-1)
xx1800003057
xx1800003036

5 Repair
Continued
Action Note
xx1800003037

• J1M.BR
Tip

when reconnecting.
xx1800003038

xx1800003039

5 Repair
Continued
Action Note
3HAC071022-001
xx1800003040
Action Note
1
DANGER

off.

• FB1
• MP1
Tip

when reconnecting.
xx1800003041
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800003042
Action Note
1
DANGER

off.
xx1800003043
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
gearbox.
xx1800003044
xx1800003045

package.
xx1800003046
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2
CAUTION

ing motors.

xx1800003064
xx1800003065
CAUTION

the pad.
xx1800003602

5 Repair
Continued
Action Note
motor.
xx1800003066
Action Note
1
DANGER

off.
2
CAUTION


gearbox.
xx1800003067
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
Tip

when refitting.
xx1800003069
xx1800003068
CAUTION

xx1800003070
xx1800003071

5 Repair
Continued
Removing the axis-1 gearbox
Action Note
1
DANGER

off.
2
CAUTION
Removing gearboxes will release axes. This

ing gearboxes.
xx1800003073
4 Pull out the gearbox.
xx1800003074
Separating the swing from the lower arm
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2 Remove the swing support.
Tip
If the swing support is hard to loosen from the

lower arm, use a plastic hammer to knock on the
swing support lightly.
xx1800003076
3 Route the upper cable package out of the swing

support.
Note
Some robots may be fitted with separate screws

and washers. During replacement, always use the
same screws (and washers) that are fitted on the
robot at delivery. Contact ABB for more informa-
tion.
xx1900002192
5 Separate the swing from the lower arm.
xx1800003078

5 Repair
Continued
Refitting the swing

Use these procedures to refit the swing.
Refitting the swing to the lower arm
Action Note
1 Refit the swing to the lower arm. Flange screws (16 pcs)
Note

tion.
xx1900002192
2 Route the cable package through the swing sup-

port.
3 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
4 Refit the swing support. Screw: M5x16 12.9 Lafre

2C2B/FC6.9 (6 pcs)
Tip Tightening torque: 6 Nm
If the swing support is hard to closely fit to the

xx1800003076

5 Repair
Continued
Refitting the axis-1 gearbox
Action Note
1 Refit the axis-1 gearbox.
Make sure the locking screw hole on the gearbox
is aligned with the notch on the swing casting.
xx1800003074
2 Secure with screws. Screw: M3x30 12.9 Lafre

2C2B/FC6.9 (12 pcs)
xx1800003073
Action Note

5 Repair
Continued
Action Note
swing.
Note

xx1800003071
xx1800003619
Action Note
2C2B/FC6.9 (13 pcs)
xx1800003069
xx1800003068

5 Repair
Continued
Action Note
Note 3HAC071022-001

xx1800003040
Action Note
1 Check that:
damages
xx1800003602

the pulley.
xx1800003085

5 Repair
Continued
Action Note
xx1800003072

2C2B/FC6.9 (3 pcs)
xx1800003065
Action Note
motor.
xx1900000040

5 Repair
Continued
Action Note
Note

xx1900000041
Action Note
3HAC071022-001
xx1800003040

Action Note
xx1800003046

5 Repair
Continued
Action Note
Tip
CAUTION

xx1800003047
xx1800003048

5 Repair
Continued
Action Note
3309-1)
Tip
CAUTION

xx1800003060
xx1800003048

5 Repair
Continued
Action Note
1 Make sure that:
gearbox.
xx1800003063
xx1800003049
xx1800003050

5 Repair
Continued
Action Note
Note

Note

xx1800003032
Action Note
2C2B/FC6.9 (3 pcs)
xx1800003043
Action Note
1


5 Repair
Continued
Action Note
• SMB.P7
• SMB.J1
• SMB.J2
Tip

xx1800002468
CAUTION

2C2B/FC6.9 (6 pcs)
xx1800002467
Action Note
CAUTION


5 Repair
Continued
Action Note
xx1800003056
2C2B/FC6.9 (6 pcs)
face
xx1800003034

xx1800003055

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003042
Action Note
• J1M.BR
• MP1
• FB1
Tip

xx1800003054

5 Repair
Continued
Action Note
xx1800003037
xx1800003036

Action Note
CAUTION


5 Repair
Continued
Action Note
xx1800003035

2C2B/FC6.9 (6 pcs)
xx1800003057
Action Note
1
CAUTION


5 Repair
Continued
Action Note
Tip

xx1800002500

• J2.C1
• J2.C2
Tip

xx1800002501
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002499

5 Repair
Continued
Action Note
1 Check that:
damages
step.
xx1800003603

xx1800003026
Tip nector.

swing support.
xx1800003027

5 Repair
Continued
Action Note
2C2B/FC6.9 (3 pcs)
xx1800002494

leys.
xx1800003028

the motor.
Note
xx1900000010

5 Repair
Continued
Action Note
timing belt.
xx1900000029
xx1800002493
xx1900000010

5 Repair
Continued
Action Note
• MP2
Tip

xx1800002495
Action Note
connector plate.
xx1800003029

• J2.FB2,3,4,5,6
• J2.MP3,4,5/6
Tip

xx1800003030
CAUTION


5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002489
Action Note
xx1800003607
Action Note
2
DANGER


5 Repair
5.5.1 Replacing the lower arm
5.5 Lower arm
Location of the lower arm

The lower arm is located as shown in the figure.
xx1800002474
Note
www.abb.com/myABB.

Lower arm (CRB 1100-4/0.58) 3HAC069056-001
Lower arm (CRB 1100-4/0.475) 3HAC069055-001
Lower arm support 3HAC069058-001

5 Repair
Continued

piece each time.
piece each time.

tion tools.
robot.
belt tension.
belt tension.

Cable straps -
Grease 3HAC029132-001 FM 222

5 Repair
Continued

support.

Action Note
calibration:
Removing the lower arm

Use these procedures to remove the lower arm.
Preparations before removing the lower arm
Action Note
procedure.

5 Repair
Continued
Action Note
• Axis 1: 0°
• Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB
1100-4/0.58)
• Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB
1100-4/0.58)
• Axis 4: 0°
• Axis 5: 0°
xx1800003289
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
xx1800002488

5 Repair
Continued
Action Note
CAUTION

xx1800002489

• J2.FB2
Tip

when reconnecting.
xx1800002490

xx1800002491
xx1800002492

5 Repair
Continued
Action Note
• MP2
Tip

when reconnecting.
xx1800002495

xx1800002493
xx1800002494
CAUTION

the pad.
CAUTION


5 Repair
Continued
Action Note
motor.
xx1800002496
Action Note
1
DANGER

off.

• J2.FB3,4,5,6
• J2.MP3,4,5/6
Tip

when reconnecting.
xx1800002497

xx1800002498

5 Repair
Continued
Action Note
1
DANGER

off.
xx1800002499
Action Note
1
DANGER

off.

nectors.
xx1800002500

5 Repair
Continued
Action Note
• J2.C1
• J2.C2
Tip

when reconnecting.
Tip
xx1800002501
Ethernet cabling).
xx1800002943
Action Note
1
DANGER

off.
xx1800003002

5 Repair
Continued
Action Note
1
DANGER

off.
xx1800003003
CAUTION

xx1800003004

• FB3
• MP3
Tip

when reconnecting.
xx1800003005

5 Repair
Continued
Action Note
xx1800003006
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
xx1800003007

5 Repair
Continued
Action Note
xx1800003008
xx1800003009
CAUTION

the pad.
xx1800003604

5 Repair
Continued
Action Note
motor.
xx1800003010
Removing the swing support
Action Note
1
DANGER

off.
2 Remove the swing support.
Tip

xx1800003079
3 Route the upper cable package out of the swing

support.
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
Note

tion.
xx1900002203
Tip
If the swing is hard to loosen from the housing,

use a plastic hammer to knock on the swing
lightly.
xx1800003081
Action Note
1
DANGER

off.
2
CAUTION

ing gearboxes.

5 Repair
Continued
Action Note
xx1800003082
xx1800003083
Pulling out the upper cable package
Action Note
1
DANGER

off.
2 Pull out the upper cable harness upwards from

the lower arm support.
xx1800003086

5 Repair
Continued
Removing the lower arm support
Action Note
1
DANGER

off.
2 Remove the lower arm support.
Tip
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
Separating the lower arm from the housing
Action Note
1
DANGER

off.
Note

tion.
xx1900002190

5 Repair
Continued
Action Note
3 Separate the lower arm from the housing.
Tip
If the lower arm is hard to loosen from the hous-

ing, use a plastic hammer to knock on the lower
arm lightly.
xx1800003090
Refitting the lower arm

Use these procedures to refit the lower arm.
Refitting the lower arm to the housing
Action Note
1 Refit the lower arm to the housing. Flange screws (16 pcs)
Note

tion.
xx1900002190
Securing the lower arm support
Action Note
inner surface of the housing, where contacts the
bearing on the lower arm support.
xx2000000059

5 Repair
Continued
Action Note
2 Refit the lower arm support. Screw: M5x16 12.9 Lafre
2C2B/FC6.9 (5 pcs)
xx1800003088
3 Route the cable package through the lower arm

support.
Action Note
xx1800003083

2C2B/FC6.9 (12 pcs)
xx1800003082

5 Repair
Continued
Action Note
Note

tion.
xx1900002203
Securing the swing support
Action Note
xx2000000058

2C2B/FC6.9 (6 pcs)

xx1800003079

5 Repair
Continued
Guiding the upper cable package down to the swing
Action Note
xx2300001788
2 Guide the upper cable package to go through the

lower arm and down to the swing.
When inserting the cable package, leave the axis-
3 motor connectors in the lower arm.
Tip
xx1800003091
Action Note
1 Check that:
damages
xx1800003604

5 Repair
Continued
Action Note
nector.
xx1800003021

2C2B/FC6.9 (3 pcs)
xx1800003009

leys.
xx1800003022

5 Repair
Continued
Action Note
the motor.
Note
xx1900000009

timing belt.
xx1900000028
xx1800003008

5 Repair
Continued
Action Note
xx1900000009
Action Note
• FB3
• MP3
Tip

xx1800003005
CAUTION


5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003006

2C2B/FC6.9 (2 pcs)
xx1800003004
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003002

5 Repair
Continued
Action Note
Tip

xx1800002500

• J2.C1
• J2.C2
Tip

xx1800002501
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002499

5 Repair
Continued
Action Note
1 Check that:
damages
step.
xx1800003603

xx1800003026
Tip nector.

swing support.
xx1800003027

5 Repair
Continued
Action Note
2C2B/FC6.9 (3 pcs)
xx1800002494

leys.
xx1800003028

the motor.
Note
xx1900000010

5 Repair
Continued
Action Note
timing belt.
xx1900000029
xx1800002493
xx1900000010

5 Repair
Continued
Action Note
• MP2
Tip

xx1800002495
Action Note
connector plate.
xx1800003029

• J2.FB2,3,4,5,6
• J2.MP3,4,5/6
Tip

xx1800003030
CAUTION


5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002489
Action Note
• Lower arm cover 2C2B/FC6.9
• Lower arm support cover Tightening torque: 1.2 Nm
• Swing cover
• Swing support cover
xx1800003610
Action Note
2
DANGER


5 Repair
5.6.1 Replacing the housing
5.6 Housing, extender unit and wrist
Location of the housing

The housing is located as shown in the figure.
xx1800002475
Note
www.abb.com/myABB.

Housing 3HAC069053-001
Labyrinth sealing ring 3HAC073218-001

5 Repair
Continued

piece each time.

tion tools.
robot.
belt tension.
belt tension.
3HAC071022-001.
axis-4 motor fitting tool - Included in the special toolkit
3HAC071022-001.
Used to refit the axis-4 motor.

Cable straps -
Grease 3HAC029132-001 FM 222
243)

5 Repair
Continued

Action Note
calibration:
Removing the housing

Use these procedures to remove the housing.
Preparations before removing the housing
Action Note
procedure.
• Axis 1: 0°
• Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB
1100-4/0.58)
• Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB
1100-4/0.58)
• Axis 4: 0°
• Axis 5: 0°
xx1800003289

5 Repair
Continued
Action Note
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
CAUTION

in following steps.
xx2000002219
xx1800002945

5 Repair
Continued
Action Note
J5.UL.
xx1800002946

• J5.C1
xx2100000293

xx1800002948
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800002949
Action Note
1
DANGER

off.

xx1800002950

• MP5
xx1800002993

5 Repair
Continued
Action Note
1
DANGER

off.

• MP6
• FB6
xx1800002994
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

xx1800002995

5 Repair
Continued
Action Note
xx1800002996

motor.
xx1800002997
Action Note
1
DANGER

off.
2 Valid for CRB 1100-4/0.475

locking screw.
xx1800003031

5 Repair
Continued
Action Note
locking screw.
xx1800003000
xx1800003001
Action Note
1
DANGER

off.
xx1800003011

5 Repair
Continued
Action Note
• FB4
• MP4
xx1800003012
Action Note
1
DANGER

off.
xx1800003013
xx1800003014

5 Repair
Continued
Action Note
1
DANGER

off.
xx1800003092
3 Pull out the upper cable harness from the housing,

out from the lower arm support.
xx1800003093
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

5 Repair
Continued
Action Note
xx1800003094
xx1800003095
CAUTION

the pad.
xx1800003605

5 Repair
Continued
Action Note
motor.
xx1800003096
Removing the pulley cover and axis-4 timing belt
Action Note
1
DANGER

off.
2
CAUTION

xx1800003097

5 Repair
Continued
Action Note
gearbox.
xx1800003098
Separating the housing
Action Note
1
DANGER

off.
Note

tion.
xx1900002191
3 Valid for CRB 1100-4/0.475

Separate the wrist from the housing.
xx1800003075

5 Repair
Continued
Action Note
4 Separate the extender unit and wrist from the
housing.
xx1800003100
Action Note
1
DANGER

off.
xx1800003003
CAUTION

xx1800003004

5 Repair
Continued
Action Note
• FB3
• MP3
Tip

when reconnecting.
xx1800003005
xx1800003006
Removing the lower arm support
Action Note
1
DANGER

off.
2 Remove the lower arm support.
Tip

xx1800003088

5 Repair
Continued
Loosening the axis-3 motor
Action Note
1
DANGER

off.
2
CAUTION

xx1800003007

xx1800003008

5 Repair
Continued
Action Note
5 Remove the timing belt from its grooves on the
motor and gearbox.
xx1800003022
Action Note
1
DANGER

off.
Note

tion.
xx1900002190
Tip

arm lightly.
xx1800003090

5 Repair
Continued
Action Note
1
DANGER

off.
2
CAUTION

ing gearboxes.
3 Remove the screws on the labyrinth sealing ring.
xx1900001425
4 Remove the labyrinth sealing ring lightly and

evenly.
xx1900001417

5 Repair
Continued
Action Note
xx1800003284
xx1800003285
Refitting the housing

Use these procedures to refit the housing.
Action Note
xx1800003285

5 Repair
Continued
Action Note
2C2B/FC6.9 (12 pcs)
xx1800003284
3 Check the O-ring.

Replace if damaged.
xx1900001424
4 Refit the labyrinth sealing ring lightly and evenly.
Note
Make sure the labyrinth sealing ring is well fitted

to the axis-3 gearbox without any deflection.
xx1900001417

5 Repair
Continued
Action Note
5 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
Action Note
Note

tion.
xx1900002190
Action Note
xx2000000059

5 Repair
Continued
Action Note
2C2B/FC6.9 (5 pcs)
xx1800003088

support.
Securing the axis-3 motor
Action Note
leys.
xx1800003022

the motor.
Note
xx1900000009

5 Repair
Continued
Action Note
timing belt.
xx1900000028
4 Tighten the motor screws. Screw: M4x12 12.9 Lafre

2C2B/FC6.9 (3 pcs)
Washer, 3HAC063985-001 (3 pcs)
xx1800003008
belt tension. New belt: 122-128 Hz

5 Repair
Continued
Action Note
xx1900000009
Action Note
• FB3
• MP3
Tip

xx1800003005
CAUTION


2C2B/FC6.9 (2 pcs)
xx1800003006

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003004
Action Note
1 Valid for CRB 1100-4/0.475
Refit the the wrist to the housing.
xx1800003075
2 Refit the extender unit and wrist to the housing.
xx1800003100

5 Repair
Continued
Action Note
3 Refit the screws and washers. Flange screws (14 pcs)
Note

tion.
xx1900002191
Refitting the axis-4 timing belt and pulley cover
Action Note
1 Install the timing belt to the gearbox pulley and
the pulley.
xx1800003098
2 Refit the pulley cover. Screw: M3x8 12.9 Lafre

2C2B/FC6.9 (3 pcs)
xx1800003097

5 Repair
Continued
Action Note
1 Check that:
damages
xx1800003605
3 Use the motor fitting tool to fix the timing belt. axis-4 motor fitting tool, included
in the special toolkit 3HAC071022-
001.
xx1900000044

5 Repair
Continued
Action Note
4 Orient the motor correctly and fit it into the hous- Motor orientation: orient the motor
ing. according to the figure below, in
Note nector.
Make sure the motor flange does not press on the

timing belt.
xx1800003287
5 Install the timing belt to the motor pulley.
xx1800003617

2C2B/FC6.9 (3 pcs)
xx1800003095
7 Remove the motor fitting tool.

5 Repair
Continued
Action Note
1 Remove the screw and washer below the housing.
xx1900000036
2 Fit an M3x25 eye bolt o the screw hole.
xx1900000037
3 Use a handheld dynamometer hooking to the eye

bolt.
xx1900000038

5 Repair
Continued
Action Note
Note

xx1900000039
5 Secure the motor with the screws. Tightening torque: 1.4 Nm
xx1800003094
6 Remove eye bolt and refit the screw and washer Plug screw: 3HAC064146-001
below the housing. Tightening torque: 2 Nm
Action Note
xx2300001789

5 Repair
Continued
Action Note
2 Insert the cable package from the lower arm sup- Cable protection tube orientation:
port, into the housing and through the axis-4 use the notch (A) on the cable pro-
gearbox. tection tube as a reference when
should be at the opposite direction
Tip to the locking screw hole on the
gearbox.
CAUTION

xx1800003017

5 Repair
Continued
Action Note
gearbox.
xx1800003018

xx1800003019
xx1800003020

5 Repair
Continued
Action Note
Note

Note

xx1800003031
xx1800003001
xx1800003000

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003013

2C2B/FC6.9 (2 pcs)
xx1800003014
CAUTION


5 Repair
Continued
Action Note
not twisted.
xx1800003618

• FB4
• MP4
Tip

xx1800003012
Action Note
1 Check that:
damages

5 Repair
Continued
Action Note
nector.
Tip

xx1800003023

2C2B/FC6.9 (3 pcs)
Note
xx1800002996

leys.
xx1800003024

5 Repair
Continued
Action Note
the motor.
Note
xx1900000007

timing belt.
xx1900000026
xx1800002995
xx1900000007

5 Repair
Continued
Action Note
• FB6
• MP6
Tip

xx1800002994
CAUTION

Action Note
• FB5
• MP5
Tip

xx1800003025
CAUTION


5 Repair
Continued
Action Note
ors.
xx1800002946
Tip

xx1800002945

• J5.C1
xx2100000293
3HAC071022-001
xx1800002948

5 Repair
Continued
Action Note
CAUTION


2C2B/FC6.9 (4 pcs)
xx2000002219
Action Note
• Lower arm cover Tightening torque: 1.2 Nm
• Lower arm support cover
• Housing cover
xx1800003611
Action Note

5 Repair
Continued
Action Note
2
DANGER


5 Repair
5.6.2 Replacing the extender unit and wrist
Location of the extender unit and wrist

The CRB 1100-4/0.58 has an extender unit connecting the housing and wrist, which
is located as shown in the figure.
xx1800002476

5 Repair
Continued
The wrist is located as shown in the figure.
xx1800002477
Note
www.abb.com/myABB.

Extender unit 3HAC069037-001 Used for CRB 1100-4/0.58.
Wrist 3HAC075794-001

5 Repair
Continued

piece each time.

tion tools.
robot.
belt tension.
belt tension.
3HAC071022-001.
3HAC071022-001.
3HAC071022-001.

Cable straps -
Grease 3HAC029132-001 FM 222
243)
5 Repair
Continued

Action Note
calibration:
Removing the extender unit and wrist

Use these procedures to remove the extender unit and wrist.
Preparations before removing the extender unit and wrist
Action Note
procedure.
• Axis 1: 0°
• Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB
1100-4/0.58)
• Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB
1100-4/0.58)
• Axis 4: 0°
• Axis 5: 0°
xx1800003289

5 Repair
Continued
Action Note
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
CAUTION

in following steps.
xx2000002219
xx1800002945

5 Repair
Continued
Action Note
J5.UL.
xx1800002946

• J5.C1
xx2100000293

xx1800002948
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800002949
Action Note
1
DANGER

off.

xx1800002950

• MP5
xx1800002993

5 Repair
Continued
Action Note
1
DANGER

off.

• MP6
• FB6
xx1800002994
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

xx1800002995

5 Repair
Continued
Action Note
xx1800002996

motor.
xx1800002997
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

5 Repair
Continued
Action Note
xx1800003293
xx1800003294

motor.
xx1800003295

5 Repair
Continued
Action Note
1
DANGER

off.
2 Valid for CRB 1100-4/0.475

locking screw.
xx1800003031

locking screw.
xx1800003000
xx1800003001

5 Repair
Continued
Action Note
1
DANGER

off.
xx1800003011

• FB4
• MP4
xx1800003012
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800003013
xx1800003014
Action Note
1
DANGER

off.
xx1800003092

5 Repair
Continued
Action Note
3 Pull out the upper cable harness from the housing,
out from the lower arm support.
xx1800003093
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

xx1800003094

5 Repair
Continued
Action Note
xx1800003095
CAUTION

the pad.
xx1800003605

motor.
xx1800003096
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2
CAUTION

xx1800003097

gearbox.
xx1800003098
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
Note

tion.
xx1900002191
3 Valid for CRB 1100-4/0.475

xx1800003299

housing.
xx1800003298
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2
CAUTION

ing gearboxes.
xx1800003300
xx1800003310
Separating the extender unit and wrist
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2 Separate the extender unit from the wrist.
xx1800003311
Refitting the extender unit and wrist

Use these procedures to refit the extender unit and wrist.
Refitting the extender unit to the wrist
Action Note
1 Align the parallel pin on the extender unit with the Parallel pin: 3HAC050369-032
pin hole on the wrist.
Note
Some robots may not have the parallel pin. In

those cases, order one and press fit it to the ex-
tender unit.
xx2100001504
xx2100001505

5 Repair
Continued
Action Note
2 Refit the extender unit to the wrist. Screw: M3x16 12.9 Lafre
2C2B/FC6.9 (16 pcs)
xx1800003311

5 Repair
Continued
Action Note
Make sure the locking screw holes on the gearbox
and extender unit or wrist are aligned with each
other.
xx1800003310
xx1800003313
xx1800003312

5 Repair
Continued
Action Note
2C2B/FC6.9 (12 pcs)
xx1800003300
Action Note
1 Valid for CRB 1100-4/0.475
xx1800003075
xx1800003100

5 Repair
Continued
Action Note
Note

tion.
xx1900002191
Action Note
the pulley.
xx1800003098

2C2B/FC6.9 (3 pcs)
xx1800003097

5 Repair
Continued
Action Note
1 Check that:
damages
xx1800003605
001.
xx1900000044

5 Repair
Continued
Action Note
Note nector.

timing belt.
xx1800003287
xx1800003617

2C2B/FC6.9 (3 pcs)
xx1800003095

5 Repair
Continued
Action Note
xx1900000036
xx1900000037

bolt.
xx1900000038

5 Repair
Continued
Action Note
Note

xx1900000039
xx1800003094
Action Note
xx2300001789

5 Repair
Continued
Action Note
2 Insert the cable package from the lower arm sup- Cable protection tube orientation:
port, into the housing and through the axis-4 use the notch (A) on the cable pro-
gearbox. tection tube as a reference when
should be at the opposite direction
Tip to the locking screw hole on the
gearbox.
CAUTION

xx1800003017

5 Repair
Continued
Action Note
gearbox.
xx1800003018

xx1800003019
xx1800003020

5 Repair
Continued
Action Note
Note

Note

xx1800003031
xx1800003001
xx1800003000

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003013

2C2B/FC6.9 (2 pcs)
xx1800003014
CAUTION


5 Repair
Continued
Action Note
not twisted.
xx1800003618

• FB4
• MP4
Tip

xx1800003012
Action Note
1 Check that:
damages

5 Repair
Continued
Action Note
2 Orient the motor correctly and fit it into the wrist. Motor orientation: orient the motor
Tip nector.

xx1800003296

2C2B/FC6.9 (3 pcs)
Note
xx1800003291

leys.
xx1800003292

5 Repair
Continued
Action Note
the motor.
Note
xx1900000008

timing belt.
xx1900000027
xx1800003290

5 Repair
Continued
Action Note
xx1900000008
Action Note
1 Check that:
damages
nector.
Tip

xx1800003023

2C2B/FC6.9 (3 pcs)
Note
xx1800002996

5 Repair
Continued
Action Note
leys.
xx1800003024

the motor.
Note
xx1900000007

timing belt.
xx1900000026
xx1800002995

5 Repair
Continued
Action Note
xx1900000007
Action Note
• FB6
• MP6
Tip

xx1800002994
CAUTION


5 Repair
Continued
Action Note
• FB5
• MP5
Tip

xx1800003025
CAUTION

Action Note
ors.
xx1800002946
Tip

xx1800002945

5 Repair
Continued
Action Note
• J5.C1
xx2100000293
3HAC071022-001
xx1800002948
CAUTION


2C2B/FC6.9 (4 pcs)
xx2000002219
Action Note

5 Repair
Continued
Action Note
• Housing cover
xx1800003612
Action Note
2
DANGER


5 Repair
5.7.1 Replacing the axis-1 motor
5.7 Motors
Location of the axis-1 motor

The axis-1 motor is located as shown in the figure.
xx1800002482
Note
www.abb.com/myABB.

face.
nector interface.

5 Repair
Continued

nector interface.
piece each time.

tion tools.
robot.
belt tension.

Cable straps -
Grease 3HAC029132-001 FM 222

Action Note

5 Repair
Continued
Action Note
calibration:
Removing the motor

Use these procedures to remove the axis-1 motor.
Preparations before removing the axis-1 motor
Action Note
procedure.
xx1800003288
3
DANGER
Turn off all:

space.

5 Repair
Continued
Action Note
1
DANGER

off.
2
CAUTION

3
WARNING


robot on its side.
xx1800003033
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
CAUTION

xx1800003034

xx1800003055

3309-1)
xx1800003056

5 Repair
Continued
Removing base covers

Action Note
1
DANGER

off.

xx1800003035

3309-1)
xx1800003057
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
• FB1
• MP1
Tip

when reconnecting.
xx1800003613

xx1800003314
Action Note
1
DANGER

off.
xx1800003042

5 Repair
Continued
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

xx1800003064
xx1800003065

5 Repair
Continued
Action Note
CAUTION

the pad.
xx1800003602

motor.
xx1800003614
Refitting the motor

Use these procedures to refit the axis-1 motor.
Action Note
1 Check that:
damages
xx1800003602

5 Repair
Continued
Action Note
nector.
xx1800003616
xx1800003615

2C2B/FC6.9 (3 pcs)
xx1800003065

5 Repair
Continued
Action Note
motor.
xx1900000040
Note

xx1900000041
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003042

5 Repair
Continued
Action Note
CAUTION

xx1800003056

5 Repair
Continued
Action Note
2C2B/FC6.9 (6 pcs)
face
xx1800003034

xx1800003055

Action Note
CAUTION


5 Repair
Continued
Action Note
xx1800003035

2C2B/FC6.9 (6 pcs)
xx1800003057
Action Note
1
CAUTION

Action Note

5 Repair
Continued
Action Note
2
DANGER


5 Repair

xx1800002483
Note
www.abb.com/myABB.

piece each time.

5 Repair
Continued

tion tools.
robot.
belt tension.
belt tension.

Cable straps -
Grease 3HAC029132-001 FM 222

Action Note

5 Repair
Continued
Action Note
calibration:
Removing the motor

Action Note
procedure.
xx1800003288
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2
CAUTION

ing motors.
xx1800002488
CAUTION

xx1800002489

• J2.FB2
Tip

when reconnecting.
xx1800002490

5 Repair
Continued
Action Note
xx1800002491
xx1800002492

• MP2
Tip

when reconnecting.
xx1800002495

xx1800002493

5 Repair
Continued
Action Note
xx1800002494
CAUTION

the pad.
CAUTION


motor.
xx1800002496
Removing the cooling pad
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2 Loosen the cooling pad bracket screws on the
motor flange.
xx1800003026
3 Use a plastic sheet with caution to remove the

cooling pad together with the bracket from the
motor. Pay attention not to scratch the motor or
damage the pad.
Refitting the motor

Refitting the cooling pad
Action Note
1 Attach the cooling pad together with the bracket Cooling pad for axis-1 and -2 mo-
to the motor. tors: 3HAC071020-001
Make sure the bracket does not exceed the motor
flange and the screw holes are aligned.
2 Refit the cooling pad bracket. Screw: M3x5 12.9 Lafre
2C2B/FC6.9 (2 pcs)
xx1800003026
Action Note
1 Check that:
damages

5 Repair
Continued
Action Note
Tip nector.

swing support.
xx1800003027

2C2B/FC6.9 (3 pcs)
xx1800002494

leys.
xx1800003028

5 Repair
Continued
Action Note
the motor.
Note
xx1900000010

timing belt.
xx1900000029
xx1800002493

5 Repair
Continued
Action Note
xx1900000010

• MP2
Tip

xx1800002495
Reconnecting the connector J2.FB2
Action Note
1 Insert the female header of the J2.FB2 connector
to the connector plate.
xx1800002491

5 Repair
Continued
Action Note
• J2.FB2
Tip

xx1800002490

CAUTION


2C2B/FC6.9 (2 pcs)
xx1800002489
Action Note

5 Repair
Continued
Action Note
xx1800003607
Action Note
2
DANGER


5 Repair

xx1800002484
Note
www.abb.com/myABB.

piece each time.

5 Repair
Continued

tion tools.
robot.
belt tension.
belt tension.

Cable straps -
Grease 3HAC029132-001 FM 222

Action Note

5 Repair
Continued
Action Note
calibration:
Removing the motor

Action Note
procedure.
xx1800003288
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800003003
CAUTION

xx1800003004

• FB3
• MP3
Tip

when reconnecting.
xx1800003005
xx1800003006

5 Repair
Continued
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
xx1800003007

xx1800003008

5 Repair
Continued
Action Note
xx1800003009
CAUTION

the pad.
xx1800003604

motor.
xx1800003010

5 Repair
Continued
Refitting the motor

Action Note
1 Check that:
damages
xx1800003604
nector.
xx1800003021

5 Repair
Continued
Action Note
2C2B/FC6.9 (3 pcs)
xx1800003009

leys.
xx1800003022

the motor.
Note
xx1900000009

5 Repair
Continued
Action Note
timing belt.
xx1900000028
xx1800003008

5 Repair
Continued
Action Note
xx1900000009
Action Note
• FB3
• MP3
Tip

xx1800003005
CAUTION


2C2B/FC6.9 (2 pcs)
xx1800003006

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003004
Refitting the lower arm covers
Action Note
xx1800003608
Action Note
2
DANGER


5 Repair

xx1800002485
Note
www.abb.com/myABB.

piece each time.

5 Repair
Continued

tion tools.
robot.
3HAC071022-001.
3HAC071022-001.
belt tension.

Cable straps -
Grease 3HAC029132-001 FM 222

Action Note

5 Repair
Continued
Action Note
calibration:
Removing the motor

Action Note
procedure.
xx1800003288
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800003011

• FB4
• MP4
xx1800003012
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

5 Repair
Continued
Action Note
xx1800003094
xx1800003095
CAUTION

the pad.
xx1800003605

5 Repair
Continued
Action Note
motor.
xx1800003096
Refitting the motor

Action Note
1 Check that:
damages
xx1800003605

5 Repair
Continued
Action Note
001.
xx1900000044
Note nector.

timing belt.
xx1800003287
xx1800003617

5 Repair
Continued
Action Note
2C2B/FC6.9 (3 pcs)
xx1800003095
Action Note
xx1900000036
xx1900000037

5 Repair
Continued
Action Note
bolt.
xx1900000038
Note

xx1900000039
xx1800003094

5 Repair
Continued
Action Note
not twisted.
xx1800003618

• FB4
• MP4
Tip

xx1800003012
Refitting the housing cover
Action Note

5 Repair
Continued
Action Note
3 Refit the housing cover. Screw: M3x8 12.9 Lafre
2C2B/FC6.9 (4 pcs)
xx1800003609
Action Note
2
DANGER


5 Repair

xx1800002486
Note
www.abb.com/myABB.



5 Repair
Continued

tion tools.
robot.
belt tension.
belt tension.
3HAC071022-001.

Cable straps -
Grease 3HAC029132-001 FM 222

Action Note

5 Repair
Continued
Action Note
calibration:
Removing the motor

Action Note
procedure.
xx1800003288
3
DANGER
Turn off all:

space.
Opening the process hub
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
CAUTION

cover!
xx2000002219
Removing the wrist cover
Action Note
1
DANGER

off.
2 Remove the wrist cover (right one when facing

the robot rear).
xx1800003315
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800002950

• MP5
xx1800002993
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

5 Repair
Continued
Action Note
xx1800003290
xx1800003291

motor.
xx1800003292

5 Repair
Continued
Refitting the motor

Action Note
1 Check that:
damages
2 Orient the motor correctly and fit it into the wrist. Motor orientation: orient the motor
Tip nector.

xx1800003296

2C2B/FC6.9 (3 pcs)
Note
xx1800003291

5 Repair
Continued
Action Note
leys.
xx1800003292

the motor.
Note
xx1900000008

timing belt.
xx1900000027
xx1800003290

5 Repair
Continued
Action Note
xx1900000008
Action Note
• FB5
• MP5
Tip

xx1800003025
CAUTION

Refitting the wrist cover
Action Note
2 Apply grease to the cover that has contacting area
with the cable package.

5 Repair
Continued
Action Note
3 Refit the wrist cover. Screw: M3x8 12.9 Lafre
2C2B/FC6.9 (7 pcs)
xx1800003315
Action Note
CAUTION


2C2B/FC6.9 (4 pcs)
xx2000002219
Action Note
2
DANGER


5 Repair

xx1800002487
Note
www.abb.com/myABB.



5 Repair
Continued

tion tools.
robot.
belt tension.
belt tension.
3HAC071022-001.

Cable straps -
Grease 3HAC029132-001 FM 222

Action Note

5 Repair
Continued
Action Note
calibration:
Removing the motor

Action Note
procedure.
xx1800003288
3
DANGER
Turn off all:

space.
Opening the process hub
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
CAUTION

cover!
xx2000002219
Action Note
1
DANGER

off.
xx1800002949
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
• MP6
• FB6
xx1800002994
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

xx1800002995

5 Repair
Continued
Action Note
xx1800002996

motor.
xx1800002997
Refitting the motor

Action Note
1 Check that:
damages

5 Repair
Continued
Action Note
nector.
Tip

xx1800003023

2C2B/FC6.9 (3 pcs)
Note
xx1800002996

leys.
xx1800003024

5 Repair
Continued
Action Note
the motor.
Note
xx1900000007

timing belt.
xx1900000026
xx1800002995
xx1900000007

5 Repair
Continued
Action Note
• FB6
• MP6
Tip

xx1800002994
CAUTION

Refitting the wrist covers
Action Note
3 Refit the wrist covers. Screw: M3x8 12.9 Lafre
2C2B/FC6.9 (14 pcs)
xx1800002949

5 Repair
Continued
Action Note
CAUTION


2C2B/FC6.9 (4 pcs)
xx2000002219
Action Note
2
DANGER


5 Repair
5.8.1 Replacing the axis-1 gearbox
5.8 Gearboxes
Location of the axis-1 gearbox

The axis-1 gearbox is located as shown in the figure.
xx1800002478
Note
www.abb.com/myABB.

Base 3HAC069048-001

5 Repair
Continued

face.
nector interface.
nector interface.
piece each time.

tion tools.
robot.
belt tension.

Cable straps -
Grease 3HAC029132-001 FM 222
243)

5 Repair
Continued

Action Note
calibration:
Removing the gearbox

Use these procedures to remove the axis-1 gearbox.
Preparations before removing the axis-1 gearbox
Action Note
procedure.
xx1800003288

5 Repair
Continued
Action Note
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
xx1800002488
CAUTION

xx1800002489

5 Repair
Continued
Action Note
• J2.FB2
Tip

when reconnecting.
xx1800002490

xx1800002491
xx1800002492

• MP2
Tip

when reconnecting.
xx1800002495

5 Repair
Continued
Action Note
xx1800002493
xx1800002494
CAUTION

the pad.
CAUTION


motor.
xx1800002496

5 Repair
Continued
Action Note
1
DANGER

off.

the locking screw.
xx1800003032
Action Note
1
DANGER

off.

• J2.FB3,4,5,6
• J2.MP3,4,5/6
Tip

when reconnecting.
xx1800002497

5 Repair
Continued
Action Note
xx1800002498
Action Note
1
DANGER

off.
xx1800002499
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
nectors.
xx1800002500

• J2.C1
• J2.C2
Tip

when reconnecting.
Tip
xx1800002501
Ethernet cabling).
xx1800002943
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2
CAUTION

3
WARNING


robot on its side.
xx1800003033
Action Note
1
DANGER

off.
2


CAUTION

CAUTION


5 Repair
Continued
Action Note
• SMB.P7
• SMB.J1
• SMB.J2
Tip

when reconnecting.
xx1800002468
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
CAUTION

xx1800003034

xx1800003055

3309-1)
xx1800003056

5 Repair
Continued

Action Note
1
DANGER

off.

xx1800003035

3309-1)
xx1800003057
xx1800003036

5 Repair
Continued
Action Note
xx1800003037

• J1M.BR
Tip

when reconnecting.
xx1800003038

xx1800003039

5 Repair
Continued
Action Note
3HAC071022-001
xx1800003040
Action Note
1
DANGER

off.

• FB1
• MP1
Tip

when reconnecting.
xx1800003041
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800003042
Action Note
1
DANGER

off.
xx1800003043
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
gearbox.
xx1800003044
xx1800003045

package.
xx1800003046
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
2
CAUTION

ing motors.

xx1800003064
xx1800003065
CAUTION

the pad.
xx1800003602

5 Repair
Continued
Action Note
motor.
xx1800003066
Action Note
1
DANGER

off.
2
CAUTION


gearbox.
xx1800003067
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
Tip

when refitting.
xx1800003069
xx1800003068
CAUTION

xx1800003070
xx1800003071

5 Repair
Continued
Action Note
1
DANGER

off.
2
CAUTION

ing gearboxes.
xx1800003073
xx1800003074

5 Repair
Continued
Refitting the gearbox

Use these procedures to refit the axis-1 gearbox.
Action Note
Make sure the locking screw hole on the gearbox
is aligned with the notch on the swing casting.
xx1800003074

2C2B/FC6.9 (12 pcs)
xx1800003073
Action Note

5 Repair
Continued
Action Note
swing.
Note

xx1800003071
xx1800003619
Action Note
2C2B/FC6.9 (13 pcs)
xx1800003069
xx1800003068

5 Repair
Continued
Action Note
Note 3HAC071022-001

xx1800003040
Action Note
1 Check that:
damages
xx1800003602

the pulley.
xx1800003085

5 Repair
Continued
Action Note
xx1800003072

2C2B/FC6.9 (3 pcs)
xx1800003065
Action Note
motor.
xx1900000040

5 Repair
Continued
Action Note
Note

xx1900000041
Action Note
3HAC071022-001
xx1800003040

Action Note
xx1800003046

5 Repair
Continued
Action Note
Tip
CAUTION

xx1800003047
xx1800003048

5 Repair
Continued
Action Note
3309-1)
Tip
CAUTION

xx1800003060
xx1800003048

5 Repair
Continued
Action Note
1 Make sure that:
gearbox.
xx1800003063
xx1800003049
xx1800003050

5 Repair
Continued
Action Note
Note

Note

xx1800003032
Action Note
2C2B/FC6.9 (3 pcs)
xx1800003043
Action Note
1


5 Repair
Continued
Action Note
• SMB.P7
• SMB.J1
• SMB.J2
Tip

xx1800002468
CAUTION

2C2B/FC6.9 (6 pcs)
xx1800002467
Action Note
CAUTION


5 Repair
Continued
Action Note
xx1800003056
2C2B/FC6.9 (6 pcs)
face
xx1800003034

xx1800003055

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003042
Action Note
• J1M.BR
• MP1
• FB1
Tip

xx1800003054

5 Repair
Continued
Action Note
xx1800003037
xx1800003036

Action Note
CAUTION


5 Repair
Continued
Action Note
xx1800003035

2C2B/FC6.9 (6 pcs)
xx1800003057
Action Note
1
CAUTION


5 Repair
Continued
Action Note
Tip

xx1800002500

• J2.C1
• J2.C2
Tip

xx1800002501
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002499

5 Repair
Continued
Action Note
1 Check that:
damages
step.
xx1800003603

xx1800003026
Tip nector.

swing support.
xx1800003027

5 Repair
Continued
Action Note
2C2B/FC6.9 (3 pcs)
xx1800002494

leys.
xx1800003028

the motor.
Note
xx1900000010

5 Repair
Continued
Action Note
timing belt.
xx1900000029
xx1800002493
xx1900000010

5 Repair
Continued
Action Note
• MP2
Tip

xx1800002495
Action Note
connector plate.
xx1800003029

• J2.FB2,3,4,5,6
• J2.MP3,4,5/6
Tip

xx1800003030
CAUTION


5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002489
Action Note
xx1800003607
Action Note
2
DANGER


5 Repair

xx1800002479
Note
www.abb.com/myABB.

piece each time.

5 Repair
Continued


tion tools.
robot.
belt tension.
belt tension.

Cable straps -
Grease 3HAC029132-001 FM 222
support.

Action Note

5 Repair
Continued
Action Note
calibration:

Action Note
procedure.
• Axis 1: 0°
• Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB
1100-4/0.58)
• Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB
1100-4/0.58)
• Axis 4: 0°
• Axis 5: 0°
xx1800003289
3
DANGER
Turn off all:

space.

5 Repair
Continued
Action Note
1
DANGER

off.
2
CAUTION

ing motors.
xx1800002488
CAUTION

xx1800002489

• J2.FB2
Tip

when reconnecting.
xx1800002490

5 Repair
Continued
Action Note
xx1800002491
xx1800002492

• MP2
Tip

when reconnecting.
xx1800002495

xx1800002493

5 Repair
Continued
Action Note
xx1800002494
CAUTION

the pad.
CAUTION


motor.
xx1800002496
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800003002
Loosening the swing support
Action Note
1
DANGER

off.
2 Loosen the swing support screws.
Tip

CAUTION
The support cannot be removed completely. Make

sure the hanging support will not wear or damage
the cable harness.
xx1800003079
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
Note

tion.
xx1900002203
Tip
If the swing is hard to loosen from the housing,

use a plastic hammer to knock on the swing
lightly.
xx1800003081
Action Note
1
DANGER

off.
2
CAUTION

ing gearboxes.
3 Move the lower arm aside a little to access the

gearbox screws.

5 Repair
Continued
Action Note
xx1800003082
xx1800003083
Removing the cable block
Action Note
1
DANGER

off.
2 Remove the cable block from the gearbox.
xx1800003084

5 Repair
Continued

Refitting the cable block
Action Note
1 Refit the cable block to the axis-2 gearbox. Screw: M2.5x6 12.9 Lafre
2C2B/FC6.9 (2 pcs)
xx1800003084
Action Note
xx1800003083

5 Repair
Continued
Action Note
2C2B/FC6.9 (12 pcs)
xx1800003082
Action Note
Note

tion.
xx1900002203
Securing the swing support
Action Note
xx2000000058

5 Repair
Continued
Action Note
2C2B/FC6.9 (6 pcs)

xx1800003079
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003002
Action Note
1 Check that:
damages

5 Repair
Continued
Action Note
step.
xx1800003603

xx1800003026
Tip nector.

swing support.
xx1800003027

5 Repair
Continued
Action Note
2C2B/FC6.9 (3 pcs)
xx1800002494

leys.
xx1800003028

the motor.
Note
xx1900000010

5 Repair
Continued
Action Note
timing belt.
xx1900000029
xx1800002493
xx1900000010

5 Repair
Continued
Action Note
• MP2
Tip

xx1800002495
Reconnecting the connector at the division point
Action Note
1 Insert the female header of the connector to the
connector plate.
xx1800002491

• J2.FB2
Tip

xx1800002490
CAUTION


5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800002489
Action Note
xx1800003607
Action Note
2
DANGER


5 Repair

xx1800002480
Note
www.abb.com/myABB.

Labyrinth sealing ring 3HAC073218-001

5 Repair
Continued

piece each time.

tion tools.
robot.
belt tension.
belt tension.

Cable straps -
Grease 3HAC029132-001 FM 222
support.
243)

5 Repair
Continued

Action Note
calibration:

Action Note
procedure.
• Axis 1: 0°
• Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB
1100-4/0.58)
• Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB
1100-4/0.58)
• Axis 4: 0°
• Axis 5: 0°
xx1800003289

5 Repair
Continued
Action Note
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
xx1800003003
CAUTION

xx1800003004

5 Repair
Continued
Action Note
• FB3
• MP3
Tip

when reconnecting.
xx1800003005
xx1800003006
Loosening the lower arm support
Action Note
1
DANGER

off.
2 Loosen the lower arm support screws.
Tip

CAUTION
The support cannot be removed completely. Make

sure the hanging support will not wear or damage
xx1800003286
the cable harness.

5 Repair
Continued
Loosening the axis-3 motor
Action Note
1
DANGER

off.
2
CAUTION

xx1800003007

xx1800003008

5 Repair
Continued
Action Note
5 Remove the timing belt from its grooves on the
motor and gearbox.
xx1800003022
Action Note
1
DANGER

off.
Note

tion.
xx1900002190
Tip

arm lightly.
xx1800003090

5 Repair
Continued
Action Note
1
DANGER

off.
2
CAUTION

ing gearboxes.
3 Remove the screws on the labyrinth sealing ring.
xx1900001425
4 Remove the labyrinth sealing ring lightly and

evenly.
xx1900001417

5 Repair
Continued
Action Note
xx1800003284
xx1800003285

Action Note
xx1800003285

5 Repair
Continued
Action Note
2C2B/FC6.9 (12 pcs)
xx1800003284
3 Check the O-ring.

Replace if damaged.
xx1900001424
4 Refit the labyrinth sealing ring lightly and evenly.
Note
Make sure the labyrinth sealing ring is well fitted

to the axis-3 gearbox without any deflection.
xx1900001417

5 Repair
Continued
Action Note
5 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
Action Note
Note

tion.
xx1900002190
Action Note
xx2000000059

5 Repair
Continued
Action Note
2C2B/FC6.9 (5 pcs)
xx1800003088

support.
Securing the axis-3 motor
Action Note
leys.
xx1800003022

the motor.
Note
xx1900000009

5 Repair
Continued
Action Note
timing belt.
xx1900000028
4 Tighten the motor screws. Screw: M4x12 12.9 Lafre

2C2B/FC6.9 (3 pcs)
Washer, 3HAC063985-001 (3 pcs)
xx1800003008

5 Repair
Continued
Action Note
xx1900000009
Action Note
• FB3
• MP3
Tip

xx1800003005
CAUTION


2C2B/FC6.9 (2 pcs)
xx1800003006

5 Repair
Continued
Action Note
2C2B/FC6.9 (2 pcs)
xx1800003004
Refitting the lower arm covers
Action Note
xx1800003608
Action Note
2
DANGER


5 Repair

xx1800002481
Note
www.abb.com/myABB.


5 Repair
Continued

piece each time.

tion tools.
robot.
3HAC071022-001.
belt tension.
3HAC071022-001.
3HAC071022-001.

Cable straps -
Grease 3HAC029132-001 FM 222
243)

5 Repair
Continued

Action Note
calibration:

Action Note
procedure.
• Axis 1: 0°
• Axis 2: 110° (CRB 1100-4/0.475) /95° (CRB
1100-4/0.58)
• Axis 3: -20° (CRB 1100-4/0.475)/ -6° (CRB
1100-4/0.58)
• Axis 4: 0°
• Axis 5: 0°
xx1800003289

5 Repair
Continued
Action Note
3
DANGER
Turn off all:

space.
Action Note
1
DANGER

off.
CAUTION

in following steps.
xx2000002219
xx1800002945

5 Repair
Continued
Action Note
J5.UL.
xx1800002946

• J5.C1
xx2100000293

xx1800002948
Action Note
1
DANGER

off.

5 Repair
Continued
Action Note
xx1800002949
Action Note
1
DANGER

off.

xx1800002950

• MP5
xx1800002993

5 Repair
Continued
Action Note
1
DANGER

off.

• MP6
• FB6
xx1800002994
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

xx1800002995

5 Repair
Continued
Action Note
xx1800002996

motor.
xx1800002997
Action Note
1
DANGER

off.
2 Valid for CRB 1100-4/0.475

locking screw.
xx1800003031

5 Repair
Continued
Action Note
locking screw.
xx1800003000
xx1800003001
Action Note
1
DANGER

off.
xx1800003011

5 Repair
Continued
Action Note
• FB4
• MP4
xx1800003012
Action Note
1
DANGER

off.
2 Pull out the upper cable harness from the housing.
Action Note
1
DANGER

off.
2
CAUTION

ing motors.

5 Repair
Continued
Action Note
xx1800003094
xx1800003095
CAUTION

the pad.
xx1800003605

5 Repair
Continued
Action Note
motor.
xx1800003096
Action Note
1
DANGER

off.
2
CAUTION

xx1800003097

5 Repair
Continued
Action Note
gearbox.
xx1800003098
Action Note
1
DANGER

off.
Note

tion.
xx1900002191
3 Valid for CRB 1100-4/0.475

xx1800003075

5 Repair
Continued
Action Note
housing.
xx1800003100
Action Note
1
DANGER

off.
2
CAUTION

ing gearboxes.
xx1800003300

5 Repair
Continued
Action Note
xx1800003310

5 Repair
Continued

Action Note
Make sure the locking screw holes on the gearbox
and extender unit or wrist are aligned with each
other.
xx1800003310
xx1800003313
xx1800003312

5 Repair
Continued
Action Note
2C2B/FC6.9 (12 pcs)
xx1800003300
Action Note
1 Valid for CRB 1100-4/0.475
xx1800003075
xx1800003100

5 Repair
Continued
Action Note
Note

tion.
xx1900002191
Action Note
the pulley.
xx1800003098

2C2B/FC6.9 (3 pcs)
xx1800003097

5 Repair
Continued
Action Note
1 Check that:
damages
xx1800003605
001.
xx1900000044

5 Repair
Continued
Action Note
Note nector.

timing belt.
xx1800003287
xx1800003617

2C2B/FC6.9 (3 pcs)
xx1800003095

5 Repair
Continued
Action Note
xx1900000036
xx1900000037

bolt.
xx1900000038

5 Repair
Continued
Action Note
Note

xx1900000039
xx1800003094
Action Note
xx2300001789

5 Repair
Continued
Action Note
2 Insert the cable package in the housing and Cable protection tube orientation:
through the axis-4 gearbox. use the notch (A) on the cable pro-
tection tube as a reference when
Tip should be at the opposite direction
to the locking screw hole (B) on the
Wrap the connectors with the masking tape. gearbox.
CAUTION

xx1800003017
xx1800003601

5 Repair
Continued
Action Note
gearbox.
xx1800003018

xx1800003019
xx1800003020

5 Repair
Continued
Action Note
Note

Note

xx1800003031
xx1800003001
xx1800003000

5 Repair
Continued
Action Note
not twisted.
xx1800003618

• FB4
• MP4
Tip

xx1800003012
Action Note
1 Check that:
damages

5 Repair
Continued
Action Note
nector.
Tip

xx1800003023

2C2B/FC6.9 (3 pcs)
Note
xx1800002996

leys.
xx1800003024

5 Repair
Continued
Action Note
the motor.
Note
xx1900000007

timing belt.
xx1900000026
xx1800002995
xx1900000007

5 Repair
Continued
Action Note
• FB6
• MP6
Tip

xx1800002994
CAUTION

Action Note
• FB5
• MP5
Tip

xx1800003025
CAUTION


5 Repair
Continued
Action Note
ors.
xx1800002946
Tip

xx1800002945

• J5.C1
xx2100000293
3HAC071022-001
xx1800002948

5 Repair
Continued
Action Note
CAUTION


2C2B/FC6.9 (4 pcs)
xx2000002219
Action Note
• Housing cover Tightening torque: 1.2 Nm
xx2000002150
Action Note

5 Repair
Continued
Action Note
2
DANGER


6 Calibration
6.1.1 Introduction and calibration terminology
6 Calibration
6.1 Introduction to calibration
6.1.1 Introduction and calibration terminology
Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 661.
Calibration terminology
Term Definition
Calibration method A collective term for several methods that might be
available for calibrating the ABB robot. Each method
contains calibration routines.
Synchronization position Known position of the complete robot where the
angle of each axis can be checked against visual
synchronization marks.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter 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.

6 Calibration
6.1.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration
position.
Standard calibration data is found on the SMB
(serial measurement board) or EIB in the robot.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the serial measurement board (SMB) or
other robot memory.
A robot calibrated with Absolute accuracy has
the option information printed on its name
plate (OmniCore).
To regain 100% Absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy after repair or maintenance that
affects the mechanical structure.
Optimization Optimization of TCP reorientation perform- Wrist Optimization
ance. The purpose is to improve reorientation
accuracy for continuous processes like weld-
ing and gluing.
Wrist optimization will update standard calib-
ration data for axes 4, 5 and 6.
Note
For advanced users, it is also possible to use

the do the wrist optimization using the RAPID
instruction WristOpt, see Technical reference
manual - RAPID Instructions, Functions and
Data types.
This instruction is only available for OmniCore
robots.
Brief description of calibration methods

Axis Calibration method
Axis Calibration is a standard calibration method for calibration of CRB 1100. It is
the recommended method in order to achieve proper performance.

6 Calibration
Continued
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
An introduction to the calibration method is given in this manual, see Calibrating
with Axis Calibration method on page 661.
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
Wrist Optimization method

Wrist Optimization is a method for improving reorientation accuracy for continuous
processes like welding and gluing and is a complement to the standard calibration
method.
The actual instructions of how to perform the wrist optimization procedure is given
on the FlexPendant.
CalibWare - Absolute Accuracy calibration

The CalibWare tool guides through the calibration process and calculates new
compensation parameters. This is further detailed in the Application
manual - CalibWare Field.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after replacements that do not include taking apart the robot
structure, standard calibration is sufficient.
The Absolute Accuracy option varies according to the robot mounting position.
This is printed on the robot name plate for each robot. The robot must be in the
correct mounting position when it is recalibrated for absolute accuracy.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 713.

6 Calibration
6.1.3 When to calibrate
6.1.3 When to calibrate
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed

If resolver values are changed, the robot must be re-calibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 657. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.
The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reachability of a robot
is changed, it needs to be re-calibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.
Robot is not floor mounted

The original calibration data delivered with the robot is generated when the robot
is floor mounted. If the robot is not floor mounted, then the robot accuracy could
be affected. The robot needs to be calibrated after it is mounted.

6 Calibration
6.2.1 Synchronization marks and synchronization position for axes
6.2 Synchronization marks and axis movement directions
6.2.1 Synchronization marks and synchronization position for axes
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, CRB 1100

4 5 6
1
xx1800002455
CAUTION
To calibrate the axis 6, the notch on the wrist must be aligned with the marked
pin hole on the tool flange. Before installing a tool on the tool flange, make sure
a visible mark has been made to the tool at the corresponding position.

6 Calibration
6.2.2 Calibration movement directions for all axes
6.2.2 Calibration movement directions for all axes
Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. 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

6 Calibration
6.3.1 Updating revolution counters on OmniCore robots
6.3 Updating revolution counters
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 655.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 660.
Correct calibration position of axis 4

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axis 4 is positioned correctly. Axis 4 can be calibrated at the
wrong turn, resulting in an incorrect manipulator calibration.
Make sure axis 4 is positioned according to the cable harness status, not only
according to the synchronization marks. Use the following procedure to check and
correct the axis 4 position.
Action Note
xx1800003011

6 Calibration
Continued
Action Note
2 Inspect the cable harness status.
The cable harness must be in vertical state as
shown in the figure.
• If the cable harness twists towards left,
proceed to step 3.
• If the cable harness twists towards right,
proceed to step 4.
xx1800003317
3 Cable harness twisting towards left

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
240 300
xx1800003318

6 Calibration
Continued
Action Note
4 Cable harness twisting towards right
Jog the axis 4 clockwise (with the operator facing
the rear) until the cable harness begins turning
left. Then, jog the axis 4 back until the cable har-
ness is in vertical state.
0 60
120 180
240 300
xx1800003319
5 Refit the housing cover. Screw: M3x8 (4 pcs)

xx1800003011
If the axis is rotated one or more turns from its calibration position before updating
the revolution counter, the correct calibration position will be lost due to non-integer
gear ratio.
At delivery the manipulator is in the correct position. Do NOT rotate axis 4 at power
up before the revolution counters are updated.

6 Calibration
Continued
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant
(OmniCore).
Action
1 On the start screen, tap Calibrate.
The calibration summary page for the mechanical unit is displayed.
2 In the Calibration Methods menu, select Revolution Counters.
3 In the Selection column select the axes for which revolution counters need to be up-
dated.
Note
A warning is displayed prompting you to check the cable harness status before pro-
ceeding with the revolution counter update for axis 4. See Correct calibration position
of axis 4 on page 657.
4 Tap Update.
A dialog box is displayed warning that the updating operation cannot be undone.
5 Tap OK to update the revolution counter.
6
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 680.

6 Calibration
6.4.1 Description of Axis Calibration
6.4 Calibrating with Axis Calibration method
Instructions for Axis Calibration procedure given on the FlexPendant

This manual contains a brief description of the method, additional information to
the information given on the FlexPendant, article number for the tools and images
of where to fit the calibration tools on the robot.
Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.
A fixed calibration pin/bushing is installed on each robot axis at delivery.
For axis 6 calibration there is one bushing on the wrist and one mounting hole on
the tool flange.
The Axis Calibration procedure described roughly:
1 A removable calibration tool is inserted by the operator into a calibration
bushing on the axis chosen for calibration, according to instructions on the
FlexPendant.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.
2 During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.
WARNING
Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.

6 Calibration
Continued
3 The axis position is stored in RobotWare with an active choice from the
operator.
Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.
Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.
Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.
Also choose this routine if the robot is wall mounted or suspended.
Note
When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.
Note
When using reference calibration with some tools, typically large or flexible tools,
oscillations in the robot can cause issues leading to failure of the calibration.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Validation
In the mentioned routines, it is also possible to validate the calibration data.

6 Calibration
Continued
Position of robot axes

The robot axes should be positioned close to 0 degrees before commencing the
calibration program. The axis chosen for calibration is then automatically run by
the calibration program to its exact calibration position during the calibration
procedure.
It is possible to position some of the other axes in positions different from 0 degrees.
Information about which axes are allowed to be jogged is given on the FlexPendant.
These axes are marked with Unrestricted in the FlexPendant window. Also the
following table shows the dependencies between the axes.
Requirements for axis positioning during calibration
Axis to calibrate
Required Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
position of
axis
Axis 1 - * * * * *
Axis 2 0 - 0 * * *
Axis 3 0 0 - * * *
Axis 4 * * * - * *
Axis 5 * * * * - X
Axis 6 * * * * * -
- Axis to be calibrated
* Unrestricted. Axis is allowed to be jogged to other position than 0 degrees.
0 Axis must be put in position 0 degrees.
X Special requirement
System containing SafeMove

SafeMove will lose its synchronization to the controller if a new calibration is done.
New calibration values have to be downloaded to SafeMove, and a new SafeMove
calibration has to be done. Make sure that the user rights admit to change the
safety settings and to synchronize SafeMove.
How to calibrate a suspended or wall mounted robot

The CRB 1100 is fine calibrated floor standing in factory, prior to shipping.
To calibrate a suspended or wall mounted robot, reference calibration could 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.
To calibrate a suspended or wall mounted robot with the fine calibration routine,
the robot must first be taken down and mounted standing on the floor.

6 Calibration
6.4.2 Calibration tools for Axis Calibration
Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
The calibration tool will eventually break from fatigue after longer period of use
and then needs to be replaced. There is no risk for bad calibrations as long as the
calibration tool is in one piece.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration bushings may cause severe damage to
the robot and/or personnel.
Equipment, etc. Article number Note

Calibration tool box, 3HAC074119-001 Delivered as a set of calibration tools.
Axis Calibration Required if Axis Calibration is the valid calib-
ration method for the robot.
The tool box also includes a unique calibra-
tion pin for CRB 1100 to be fitted to the tool
flange during calibration of axis 6.
Examining the calibration tool

Check prior to usage
Before using the calibration tool, make sure that the tube insert, the plastic
protection and the steel spring ring are present.
WARNING
If any part is missing or damaged, the tool must be replaced immediately.
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring

6 Calibration
Continued
Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following
measures should be checked.
• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on
calibration tool size).
• Straightness within 0.005 mm.
xx1500000951
A Outer diameter
Periodic check of the calibration tool for the tool flange (3HAC058238-001)
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.
.
xx1600001142
A Outer diameter

6 Calibration
6.4.3 Installation locations for the calibration tools
Location of fixed calibration items

This section shows how the robot is equipped with items for installation of
calibration tools for Axis Calibration (fixed calibration pins and/or bushings).
Installed calibration tools are not shown.
A fixed calibration pin and a bushing for the movable calibration tool are located
on each axis as follows.
If there is not enough space on an axis to install a fixed calibration pin, the axis is
equipped with two bushings instead, for installation of two calibration tools when
calibration is carried out. This is shown in the figure.
For axis 6 there is only one bushing, the second calibration tool is installed at the
mounting flange of the turning disk.
xx1800003320

6 Calibration
Continued
xx1800003514
xx1800003515
Spare parts
When calibration is not being performed, a protective cover and an o-ring should
always be installed on the fixed calibration pin as well as a protective plug, included
a sealing, in the bushing. Replace damaged parts with new.

Protective plug for bushing 3HAC059556-001 Replace if damaged or missing.

6 Calibration
Continued

Protective plug for bushing, 3HAC059557-001 Used with protection type Clean Room.
Clean Room Replace if damaged or missing.
Calibration pin cover, 6 mm 3HAC061926-001 Replace if damaged or missing.

6 Calibration
6.4.4 Axis Calibration - Running the calibration procedure
Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration holes may cause severe damage to the
robot and/or personnel.
Equipment, etc. Article number Note

Calibration tool box, Axis 3HAC074119-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
calibration method for the robot.
The tool box also includes a unique
calibration pin for CRB 1100 to be fitted
to the tool flange during calibration of
axis 6.
Clean cloth -
Spare parts

Protective plug for bushing 3HAC059556-001 Replace if damaged or missing.
Protective plug for bushing, 3HAC059557-001 Used with protection type Clean Room.
Clean Room Replace if damaged or missing.
Calibration pin cover, 6 mm 3HAC061926-001 Replace if damaged or missing.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure.
After the calibration method has been started on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine. The routines are described in Routines in the
calibration procedure on page 662.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.
4 Validate the synchronization marks.
6 Calibration
Continued
5 The robot moves to preparation position.

6 Remove the protective cover from the fixed pin and the protection plug from
the bushing, if any, and install the calibration tool.
When calibrating axis 5, remove the protective cover from the fixed pin using
a tweezer, and install the calibration tool.
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protective cover on the fixed
pin and the protection plug in the bushing, if any.
After the calibration of axis 5, refit the protective cover on the fixed pin for
axis 5 using a tweezer.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.
Action Note
1
DANGER
While conducting the calibration, the robot needs

to be connected to power.
Make sure that the robot's working area is empty,
as the robot can make unpredictable movements.
2 Wipe the calibration tool clean. Use a clean cloth.
Note
The calibration method is exact. Dust, dirt or color

flakes will affect the calibration value.
3 Check if the standard calibration data for axes 4, If the data is optimized, the calibra-
5 or 6 are updated with wrist optimization. tion routine Wrist Optimization
This is shown in the calibration overview/summary must be re-run after standard calib-
window on the FlexPendant. ration.
See Calibrating with Wrist Optimiza-
tion method on page 677.
Starting the calibration procedure

Use this procedure to start the Axis Calibration routine on the FlexPendant.
Action Note
1 Tap the calibration icon and enter the calibration
main page.

6 Calibration
Continued
Action Note
2 All mechanical units connected to the system are
shown with their calibration status.
Tap the mechanical unit in question.
Note
For RobotWare 7, the mechanical unit page is

displayed only if there is more than one mechan-
ical unit available.
3 The calibration method used at ABB factory for The FlexPendant will give all inform-
each axis is shown, as well as calibration method ation needed to proceed with Axis
used for the robot during last field calibration. Calibration.
4 Valid for RobotWare 7
Tap Calibration Methods on the right pane and
then tap Calibration. The software will automatic-
ally call for the procedure for the valid calibration
method.
5 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 669.
Fitting of calibration tools

The figures show the calibration tool in contact with the fixed pin on each axis.
The position of the complete robot shown for each axis is only an example.
In order for the axis to be able to be moved to calibration position, or in order for
getting proper access to the calibration bushing, other axes might need to be
jogged to positions different from 0 degrees. Information about which axes are

6 Calibration
Continued
allowed to be jogged will be given on the FlexPendant. These axes are marked
with Unrestricted in the FlexPendant window.
Calibration tools in contact
Axis 1 Axis 2
xx1900000113 xx1900000114
Axis 3 Axis 4
xx1900000115
xx1900000116

6 Calibration
Continued
Calibration tools in contact

Axis 5 Axis 6
Make sure to orient the tool flange calibration
tool correctly.
xx1900000117
xx1900000118
Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
The three-position enabling device on the Press and hold the three-position enabling
FlexPendant has been released during robot device and press Play.
movement.
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure.
If the calibration tool is in contact the robot
axis needs to be jogged in order to release
the calibration tool. Jogging the axis in wrong
direction will cause the calibration tool to
break. Directions of axis movement is shown
in Calibration movement directions for all
axes on page 656
Axis Calibration with SafeMove option

To be able to run Axis Calibration, SafeMove needs to be unsynchronized. The
Axis Calibration routine recognizes if the robot is equipped with SafeMove and will
force SafeMove to unsynchronize automatically.
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine. When a warning message is displayed, tap Acknowledge
to confirm the unsynchronized state and continue Axis Calibration procedure.
CAUTION
SafeMove must be synchronized after the calibration is completed.

6 Calibration
Continued
After calibration
Action Note
1 Reinstall the protective cover on the fixed calibra-

tion pin on each axis, directly after the axis has
been calibrated.
Replace the cover with new spare part, if missing
or damaged.
xx1900001421
Calibration pin cover, 6 mm:

3HAC061926-001
2 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. 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.
3 If the standard calibration data for axes 4, 5 or 6 See Calibrating with Wrist Optimiz-
should be updated with wrist optimization, run the ation method on page 677.
calibration routine Wrist Optimization.

6 Calibration
6.4.5 Reference calibration
Brief introduction to Reference Calibration

Reference calibration is a faster method compared to Fine calibration, as it refers
to a previously made calibration.
1 Create a backup of the current robot system.
2 Check that the active calibration offset values corresponds to the values on
the calibration label (located on the lower arm or the base).
3 Jog the manipulator so that all axes are in zero position (ex use MoveAbsJ
instruction). Check that all axis scales are aligned with calibration marks.
4 If the scales differ from calibration marks it might depend on wrong turns of
the revolution counters. Make a marker line on the corresponding axis to be
able to validate the result of the calibration. If more than one motor revolutions
are wrong, the calibration will fail.
5 Use a verification position. This is especially recommended if all axes were
not aligned with the synchronization marks (step 3). Reuse an existing
position that is suitable and accurate so it can be used to validate the repair.
Use a position where a deviation in axis calibration gives a big deviation in
positioning. Note! Check the position after each repair in one axis.
6 Use Reference calibration to save reference values for all axes that is to be
replaced. Make sure that the values are saved in RobotStudio or FTP program.
The files are located in "Active system folder name/HOME/RefCalibFiles".
7 Perform the repair.
8 Make sure that the tooling and process equipment are the same as when
creating the reference. Use Reference calibration to update the system with
new calibration offset value for the repaired axis.
9 Check the position against the verification position (step 5).
10 Proceed with the repair of the next axis, if necessary, and repeat (step 8-9)
for every axis.
11 (For system containing SafeMove) Download new calibration values to
SafeMove. Use Visual SafeMove in RobotStudio.
12 (For system containing SafeMove) Synchronize SafeMove to activate
SafeMove.
13 Perform test run.
14 Update the calibration label with new resolver values (calibration values).
Manual tuning of calibration offset

Manual tuning of calibration offset is normally not needed, but can be useful in
some situations. The requirement to do manual tuning is that there is a known
accurate position, that worked accurately before the repair (step 5, see Brief
introduction to Reference Calibration on page 675).
Example "Adjust axis 4":
1 Create a backup.

6 Calibration
Continued
2 Run the manipulator to the verification position. (The manipulator position

is now deviating from the verification position.)
3 Read and note current axis 4 value in degrees (example: 96.3 degrees).
4 Manually jog, only axis 4, so that the manipulator is correctly positioned to
the verification position.
5 Read and note current axis 4 value in degrees (example: 94.2 degrees).
6 Move the manipulator to its calibration position.
7 Calculate the angle difference (ie 96.3-94.2=2.1 degrees).
8 Manually jog axis 4 the calculated angle difference (-2.1). NOTE! The direction
+/- shall be the same direction as the direction used when axis 4 was manually
jogged to coincide with the verification process. In the example -2.1 degrees.
9 Make a new manual fine calibration of axis 4 with axis in -2.1 degrees position.
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.

6 Calibration
6.5 Calibrating with Wrist Optimization method
When to run Wrist Optimization

Wrist Optimization routine is run to improve TCP reorientation performance.
Calibrating the robot with standard calibration method overwrites the optimized
positions of axes 4, 5, 6. Re-run the Wrist Optimization routine after standard
calibration to re-achieve the optimized positions of the wrist axes.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine Wrist Optimization.
2 Modify targets for 4-point tool frame definition, in Wrist Optimization routine.
Tip
Select positions with large reorientations around the TCP. For best results,
make sure that axis 4 and 5 have large movements.
a Jog the robot to an appropriate position,
A, for the first approach point.
Use small increments to accurately posi-
tion the tool tip as close to the reference
point as possible.
b Tap Modify Position to define the point.
c Repeat for each approach point to be
defined, positions B, C, and D.
Jog away from the fixed world point to
achieve the best result. Just changing the
tool orientation will not give as good a
result.
en0400000906
3 Improved calibration data to the wrist axes is identified and presented.

4 Optimized positions for the wrist axes are presented.

6 Calibration
Continued
5 The robot moves to the optimized positions for the wrist axes and
automatically overwrites previous calibration data.
WARNING
Robot moves automatically when pressing Calibrate.
6 Wrist optimization is finished.

7 Redefine / verify TCP for all tools.

6 Calibration
6.6 Verifying the calibration
6.6 Verifying the calibration
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 680.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 655.
3 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.

6 Calibration
6.7 Checking the synchronization position
6.7 Checking the synchronization position
Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jog window on the FlexPendant.

6 Calibration
6.7.1 Checking the synchronization position on OmniCore robots
6.7.1 Checking the synchronization position on OmniCore robots
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 Tap Code.
2 Create a new program.
3 Use MoveAbsJ in the Add Instruction menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 655 and Updating revolution
counters on page 657.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 Tap Jog.
2 From the Mechanical unit list select a
mechanical unit.
3 From the Motion mode section, select an
axis-set that need to be jogged.
For example, to jog axis 2, select the axis
set Axis 1-3.
4 Follow the screen instruction on joystick
movements to understand the direction of
the axis that you want to move and move
the joystick.
5 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
6 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 655 and
date the revolution counters. Updating revolution counters on page 657.

7 Troubleshooting
7.1 Introduction to troubleshooting
7 Troubleshooting
Introduction
The product manual and the circuit diagram contains information that can be good
when troubleshooting.
For OmniCore, all event logs from the software can be seen on the FlexPendant,
or in Technical reference manual - Event logs for RobotWare 7.
Make sure to read through the section Safety on page 17 before starting.
Troubleshooting strategies
1 Isolate the fault to pinpoint the cause of the problem from consequential
problems.
2 Divide the fault chain in two.
3 Check communication parameters and cables.
4 Check that the software version is compatible with the hardware.
Work systematically
1 Take a look around to make sure that all screws, connectors, and cables are
secured, and that the robot and other parts are clean, not damaged, and
correctly fitted.
2 Replace one thing at a time.
3 Do not replace units randomly.
4 Make sure that there are no loose screws, turnings, or other unexpected
parts remaining after work has been performed.
5 When the work is completed, verify that the safety functions are working as
intended.
Keep a track of history

• Make a historical fault log to keep track of problems over time.
• Consult those working with the robot when the problem occurred.
Basic scenarios
What to look for during troubleshooting depends on when the fault occurred. Was
the robot recently installed or was it recently repaired? The following table gives
hints on what to look for in specific situations.
The robot has recently Check:
been installed • the configuration files
• connectors
• options and their configuration
• changes in the robot working space/movements.

7 Troubleshooting
Continued

been repaired • all connections to the replaced part
• power supplies
• that the correct part has been fitted
• the last repair documents.
The robot recently had a Check:
software upgrade • software versions
• compatibilities between hardware and software
• options and their configuration
been moved from one site • connections
to another (an already • software versions
working robot)

7 Troubleshooting
7.2 Oil and grease stains on motors and gearboxes
7.2 Oil and grease stains on motors and gearboxes
Description
The area surrounding the motor, gearbox or seal lip shows signs of oil leaks. This
can be at the base, closest to the mating surface, at the furthest end of the motor
at the resolver, or around the joints of the covers (closest to the edge) on the robot
surface.
Consequences
Besides the dirty appearance, in most cases there are no serious consequences
if the leaked amount of oil is very small.
Possible causes
The symptom can be caused by:
• Leakage of rust preventives or mounting grease. This should be wiped off.
• Leaking sealing between gearbox and motor.
• Gearbox overfilled with oil.
• Gearbox oil too hot.
Recommended actions
The following actions are recommended:
Action Information
1
CAUTION
Allow hot parts to cool down.
2 Wipe off the oil or grease, see Cleaning the CRB If the oil spill is small, this step is
1100 on page 172. sufficient.
Monitor the robot over time to see if new oil or
grease occurs.
3 Check the gearbox oil level.
4 Too hot gearbox oil may be caused by: Robots performing certain, ex-
• Incorrect oil quality or level. tremely heavy duty work cycles
• The robot work cycle runs a specific axis may be fitted with vented oil plugs.
too hard. Investigate whether it is possible These are not fitted to normal duty
to program small "cooling periods" into the robots, but can be purchased from
application. your local ABB representative.
• Overpressure created inside gearbox.
5 Inspect all sealings and gaskets between motor
and gearbox. Replace broken parts.

7 Troubleshooting
7.3 Mechanical noise or dissonance
7.3 Mechanical noise or dissonance
Description
Mechanical noise or dissonance that has not been observed before can indicate
problems in bearings, motors, gearboxes, or similar. Be observant of changes over
time.
A faulty bearing often emits scraping, grinding, or clicking noises shortly before
failing.
A humming resonance sound can occur without being an error. Mechanical
resonance sound is a physical phenomenon in mechanical structures. It has no
impact on product performance or lifetime. Adjusting the robot movement speed
out of the range that causes the resonance will eliminate the sound.
Consequences
Failing bearings cause the path accuracy to become inconsistent, and in severe
cases, the joint can seize completely.
Possible causes
• Worn bearings.
• Contaminations have entered the bearing grooves.
• Loss of lubrication in bearings.
• Loose heat sinks, fans, or metal parts.
If the noise is emitted from a gearbox, the following can also apply:
• Overheating.
Recommended actions
Action Information
1
CAUTION
2 Verify that the service is done according to

the maintenance schedule.
3 If a bearing is emitting the noise, determine
which one and make sure that it has suffi-
cient lubrication.
4 If possible, disassemble the joint and meas-
ure the clearance.
5 Bearings inside motors are not to be re-
placed individually, but the complete motor
is replaced.
6 Make sure the bearings are fitted correctly.
7 Tighten the screws if a heat sink, fan, or
metal sheet is loose.

7 Troubleshooting
7.4 Manipulator collapses on power down
7.4 Manipulator collapses on power down
Description
The manipulator is able to work correctly while Motors ON is active, but when
Motors OFF is active, one or more axes drops or collapses under its own weight.
The holding brakes (normally one in each motor), is not able to hold the weight of
the manipulator arm.
Consequences
For a heavy robot, the collapse can cause severe injury to personnel working in
the area or severe damage to the robot and/or surrounding equipment.
For a small robot, the collapse can cause injury to personnel working close to the
robot or damage to the robot and/or surrounding equipment.
Possible causes
• Faulty brake.
• Faulty power supply to the brake.
Recommended actions
Action Information
1 Determine which motor(s) causes the robot
to collapse.
2 Check the brake power supply to the col- See the circuit diagram.
lapsing motor during the Motors OFF state.
3 Remove the resolver or resolver cover of If found faulty, the motor must be replaced
the motor to see if there are any signs of as a complete unit.
oil leaks.
4 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.

7 Troubleshooting
7.5 Motor temperature too high
7.5 Motor temperature too high
Description
The robot stops and the motor temperature for joint arg is too high.
Consequences
It is not possible to continue until the motor has cooled down. The system goes to
Motors Off.
Possible causes
• The values for payload and arm load are not consistent with the actual ones.
• The value for ambient temperature setting in the controller is not consistent
with the actual operating temperature environment.
• The user program may contain too much high acceleration and deceleration
of the joint.
• Gravity torque or external forces for the joint can also be too high.
Recommended actions
Action Information
1
CAUTION
2 Verify that the values for payload and arm

load are set correctly.
3 Verify that the value for ambient temperature
setting in the controller is consistent with the
actual operating temperature environment.
4 Rewrite the user program to reduce the mo- The ways could be but not limited to op-
tor utilization. timizing robot movement cycle, adjusting
acc, dec as well as external force, adding
wait time, and introducing alternative
path/RAPID, etc.

7 Troubleshooting
7.6 Robot vibration during low speed movement
Description
Robot vibration, especially at the wrist, can be observed when the robot moves at
a low speed.
Consequences
Slight vibration that is invisible will not affect the use of the robot. However, a clear
robot vibration will decrease path accuracy and affect user applications.
Possible causes
Vibration might be caused by external factors:
• Incorrect robot installation
• Insufficient stiffness of robot pedestal
• Resonance with nearby moving machines
• Incorrect definition of payloads and tools
• Part malfunction, such as motor, gearbox, timing belt or main cable harness
Vibration might also happen when the robot moves at a low speed or in some
specific poses. This is generally caused by mechanical resonance between servo
system, gearbox and robot body, which is considered as an internal factor. Such
vibration is a normal physical phenomenon, which is not a quality-related issue.
Recommended actions
Action Information
1 Verify that the robot is firmly secured to the The attachment screws used for securing
foundation. the robot to the foundation must be
tightened with correct tightening torque.
See Orienting and securing the robot on
page 57.
2 Verify that the stiffness of robot pedestal
meets the requirement.
3 Turn off all the moving machines near to the
robot and then check robot vibration again.
If no vibration can be observed any more,
move either the machines or the robot to
another place to remove the external reson-
ance source.
4 Verify the payload and tools are correctly
defined.
If not correctly defined, redefine them.
5 Jog the robot joint by joint to verify the
functionality of each joint.
If anything abnormal is found on a joint, loc-
ate the possible malfunction part with other
measurements such as noise, warnings on
the FlexPendant, and then replace it.

7 Troubleshooting
Continued
Action Information
6 Make sure all the external factors have been
checked and excluded.
If vibration remains, it might be caused by
the internal factor. Contact ABB for further
assistance.

7 Troubleshooting
7.7 Communication failure between PROFIsafe-based laser scanner, PLC, and controller
7.7 Communication failure between PROFIsafe-based laser scanner, PLC, and

controller
Description
The ProfiNet LED on the laser scanner is not lit up, indicating that the profinet
communication between the laser scanner, PLC, and OmniCore controller fails to
be set up. However, the cable connection is properly connected and necessary
parameters are correctly set during the laser scanner configuration.
This issue may occur when PROFIsafe-based laser scanner(s) is connected.
Consequences
Communication fails to be set up between the laser scanner, PLC, and OmniCore.
The safety separation function with the laser scanner cannot be applied.
Possible causes
The firewall for the ProfiNet network is disabled.
Recommended actions
1 Open RobotStudio.
2 In the Controller tab page, choose Communication from the Configuration
group.
3 Select Firewall Manager in the Type pane.
4 Set Enable on Public Network to Yes for the network service ProfiNet.

7 Troubleshooting
7.8 Communication failure between PLC and controller
Description
The OmniCore controller and PLC are configured with all parameters correctly set.
However, the communication between the OmniCore controller and PLC still fails.
This issue may occur when the PROFIsafe-based laser scanner(s) is connected.
Consequence
The safety configurations do not take effect.
Possible causes
During configuration of communication between the OmniCore controller and PLC,
the PROFIsafe device information must be configured on the OmniCore controller’s
side first. Otherwise, the configured signals will not be saved in the safety module
in the OmniCore controller.
Recommended actions
2 In the Controller tab page, choose Visual SafeMove from Safety in the
3 Check the Safe I/O configurations.
For robots running RobotWare 7.5 or earlier, the following signals can be
observed.
xx2100000511

7 Troubleshooting
Continued
For robots running RobotWare 7.6 or later, the following signals can be
observed.
xx2200000304
4 If the signals cannot be observed, choose I/O Engineering Tool from

Configuration in the Configuration group.
5 Go back to the Visual SafeMove window and write the SafeMove
configurations to the controller again.
You will observe the signals and the communication is correctly set up.

7 Troubleshooting
7.9 Communication failure between scalable I/O device and controller
7.9 Communication failure between scalable I/O device and controller
Description
The OmniCore controller and scalable I/O device DSQC1042 are configured with
all parameters correctly set. However, the communication between the OmniCore
controller and scalable I/O device still fails.
This issue may occur when the SafetyIO-based laser scanner(s) is connected.
Consequence
The safety configurations do not take effect.
Possible causes
During configuration of communication between the OmniCore controller and
scalable I/O device, the scalable I/O device information must be configured on the
OmniCore controller’s side first. Otherwise, the configured signals will not be saved
in the OmniCore controller.
Recommended actions
2 In the Controller tab page, choose Visual SafeMove from Safety in the
3 Check the Safe I/O configurations.
The following signals can be observed.
xx2200000305
4 If the signals cannot be observed, choose I/O Engineering Tool from

Configuration in the Configuration group.
5 Go back to the Visual SafeMove window and write the SafeMove
configurations to the controller again.
You will observe the signals and the communication is correctly set up.

7 Troubleshooting
7.10 Errors related to stopped background task T_SWIFTI_LED
7.10 Errors related to stopped background task T_SWIFTI_LED
Description
Execution errors are reported because the background task T_SWIFTI_LED is
stopped.
Consequences
Program execution is halted.
Possible causes
The I/O module is changed or reset.
Recommended actions
1 Tap I/O in the main page of the FlexPendant.
2 Check the device status, whether the CabinetIO device with address
192.168.125.100 is in Not connected state, and there is another device in
Unknown state.
3 If in previous situation, tap the menu button after the unknown device and
tap Identify in the list.
Verify whether the unknown device is the I/O module installed on the
controller. If yes, the LED blinks on the I/O module.
4 Tap Configure in the list for the unknown device.
5 In the displayed I/O Modernization window, choose Update device in the
Configuration area and select CabinetIO from the drop-down list.
This will update the unknown device to CabinetIO.
6 Tap Apply.
The system works normally.

7 Troubleshooting
7.11 Unable to change speed value in FlexPendant
7.11 Unable to change speed value in FlexPendant
Description
In manual mode, the Speed scrollbar in the FlexPendant cannot be dragged to edit
the speed.
This issue may occur when robot is running in RobotWare 7.5 or an earlier version.
Consequences
Robot movement speed cannot be edited in manual mode in FlexPendant.
Possible causes
The speed control module uses the value of the system input whose Action is Set
speed to control the actual movement speed. If the communication between the
OmniCore controller and laser scanner fails, the controller considers this situation
as that the protecting area is triggered, and the speed will be limited to 0%. If the
communication failure remains when the operating mode is changed to Manual,
the Set speed value is still valid.
Recommended actions
1 In the FlexPendant, tap I/O in the main page.
2 Reset the StartInProtecting DO.
The speed limitation will be released.

7 Troubleshooting
7.12 Movement in Safe area not in full speed or at zero speed
7.12 Movement in Safe area not in full speed or at zero speed
Description
The speed in the Safe area is not at the full speed specified in the motion instruction
or even at zero speed after the SST/TSP violation is triggered.
This issue may occur when robot is running in RobotWare 7.5 or an earlier version.
Consequences
Robot cannot move in the specified speed, that is, in slow speed, or even stops
movement in the Safe area.
Possible causes
Before the SST/TSP is triggered, the system triggers Protecting or Warning area
speed control first. In this case, the speed control module uses the value of
SpeedRefresh to control the robot movement speed. At the time that the SST/TSP
triggers the robot stopping, the speed control has already changed by the
SpeedRefresh value which is 0 in Protecting area and 20 in Warning area.
When users are back to the Safe area and restart or step the program after the
SST/TSP violation, the SpeedRefresh value that refresh the speed to 100 does
not take effect. That is, the speed is still controlled by the SpeedRefresh value 0
or 20. Although the speed shown in the FlexPendant is 100%, the actual speed is
still controlled by the combination of the SpeedRefresh value and the speed set
in motion instruction, which will result in the movement stopping or moving in slow
speed in the Safe area.
Furthermore, when the STT violation is triggered, the manipulator triggers Cat0 or
Cat1 emergency stop. If the user tries to start program in the Protecting area but
is not in the STT area, the robot will start moving a short path to regain the previous
point and then stop. In this case, the speed is restricted to 0.
For more details, see Strategies (RobotWare 7.5) on page 155.
Recommended actions
Users could perform either of the following solutions:
• Reset the program pointer and start the program in the Safe area again.
• Enter the Warning area but not trigger the TSP supervision violation and then
back to the Safe area again.

7 Troubleshooting
7.13 Unable to remove or reselect installed options in Collaborative Speed Control add-in
7.13 Unable to remove or reselect installed options in Collaborative Speed Control

add-in
Description
The installed lead-through or laser scanner options fail to be removed or reselected
in the Collaborative Speed Control add-in using the Modify Installation function.
Consequence
• Lamp indicator does not light up after the installed options are reselected.
• Modules of the SpeedHandling function remain in task T_ROB1 after the
installed options are removed.
• Existing template SafeMove configuration file is not removed after the installed
options are removed or not synchronized with new configuration file for the
new option after the installed options are reselected.
Recommended actions
1 Reset the template SafeMove configuration file to factory settings and apply
it to the controller.
2 For scenarios to remove options, de-select the checkboxes of the options
that require to be removed in the Collaborative Speed Control add-in and
apply it to the controller.
3 For scenarios to reselect options, de-select the checkboxes of the options
not required first and then select the required options in the Collaborative
Speed Control add-in and apply it to the controller.
4 Reset the RAPID programs and parameters in RobotStudio and restart the
controller.
5 Load the template SafeMove configuration file using the SafeMove
configurator app on FlexPendant.

7 Troubleshooting
7.14 Unexpected robot movement when starting the program in Protecting Area
7.14 Unexpected robot movement when starting the program in Protecting Area
Description
The robot moves unexpectedly in a speed not larger than 250 mm/sec when the
user starts the program in Protecting area, in which situation the robot should be
stopped and stand still.
Consequence
The unexpected robot movement may cause damages or injuries to objects or
persons within its movement range.
Possible causes
The robot moves in mentioned scenario only when all of the following conditions
are met:
• The function ISH_b_FunctionlityIsUsed in RAPID program
InternalSpeedHandling_User is set to TRUE.
• The template SafeMove configuration file provided with the Collaborative
Speed Control add-in is not loaded, or is loaded but Global_SST configuration
is removed or the ISH_UserMODE_bNot_IntemitCollab is set to 1.
• The system is in Auto mode or Manual Full Speed mode.
• The robot was stopped during running a program, and then manually moved
to another position which is within the range of the robot return path.
• The user stands in Protecting area and restarts the program using
FlexPendant.
Recommended actions
Reset the template SafeMove configuration file to factory setting and then load the
configuration file provided with the Collaborative Speed Control add-in. See detailed
procedures in The SafeMove configurator app on FlexPendant on page 107.

7 Troubleshooting
7.15 Program execution stops because no safety configuration template loaded
7.15 Program execution stops because no safety configuration template loaded
Description
The robots installed with the Collaborative Speed Control add-in that provides
safety configuration templates for easy use. However, the templates are not loaded
after selecting Enable Edit Mode and Use template configuration in the SafeMove
configurator app on FlexPendant.
When executing the program, a message box is displayed, prompting users to load
templates from the controller file system.
Consequence
Program execution cannot proceed until a safety configuration template is loaded.
Possible causes
If the robot operating in RW 7.12 with a Collaborative Speed Control add-in earlier
than 1.2.1, the safety configuration templates are unavailable in the controller file
system for loading.
Recommended actions
1 Check the Collaborative Speed Control add-in version and make sure the
version 1.2.1 is installed.
2 Log in the FlexPendant as a user with safety user grants.
4 Tap Enable Edit Mode.
5 Tap Load Configuration From File from the Context menu (...).
6 Browse templates in the controller file folder:
"PRODUCTS/CollaborativeSpeedControl/SafeMove/<your robot
type>/Templates" and select the template for your option.
7 Tap OK and then Yes to load the template.
8 Tap Write to controller.
9 Select Apply to controller to proceed.

8 Decommissioning
8.1 Introduction to decommissioning
8 Decommissioning
8.1 Introduction to decommissioning
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
Note
The decommissioning process shall be preceded by a risk assessment.
Disposal of materials used in the robot

All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. 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.
See also Environmental information on page 702.
Transportation
Prepare the robot or parts before transport, this to avoid hazards.

8 Decommissioning
8.2 Environmental information
Introduction
ABB robots contain components in different materials. During decommissioning,
all materials should be dismantled, recycled, or reused responsibly, according to
the relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Materials used in the product

The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Base, base adapter, swing, swing support, lower arm,

lower arm support, swing, covers, motors, gearboxes,
SMB unit, etc
Batteries, Lithium Serial measurement board
Copper Cables, motors
Lead Serial measurement board
Neodymium Motors
Oil, grease Gearboxes, process hub, etc
Plastic/rubber Cables, SMB unit, gearboxes, timing belt, cooling
pads, connector kits, etc
Steel Base, swing, lower arm, extender unit, wrist, motors,
gearboxes, SMB unit, etc

8 Decommissioning
Continued
China RoHS symbol

The following symbol shows the information to hazardous substances and the
environmental protection use period of CRB 1100 according to "Management
Methods for the Restriction of the Use of Hazardous Substances in Electrical and
Electronic Products (SJ/T 11364-2014) ".
xx1900000803
Green symbol with "e" in it: The product does not contain any hazardous substances
exceeding concentration limits and is a green environmentally friendly product
which can be recycled.
Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:
• Spills can form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.

8 Decommissioning
8.3 Scrapping of robot
8.3 Scrapping of robot
Note
The decommissioning process shall be preceded by a risk assessment.
Important when scrapping the robot
DANGER
The risk assessment should consider hazards arising in the decommissioning,

such as, but not limited to:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.
• A used robot does not have the same performance as on delivery. Springs,
brakes, bearings, and other parts might be worn or broken.

9 Reference information
9.1 Introduction
9.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

9.2 Applicable standards
9.2 Applicable standards
General
The product is compliant with ISO 10218-1:2011, Robots for industrial environments
- Safety requirements - Part 1 Robots, and applicable parts in the normative
references, as referred to from ISO 10218-1:2011. In case of deviation from ISO
10218-1:2011, these are listed in the declaration of incorporation. The declaration
of incorporation is part of the delivery.
Robot standards
Standard Description
ISO 9283 Manipulating industrial robots – Performance criteria and re-
lated test methods
ISO 9787 Robots and robotic devices – Coordinate systems and motion
nomenclatures
ISO 9946 Manipulating industrial robots – Presentation of characteristics
Other standards used in design
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements, normative reference from ISO 10218-
1
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design, normative reference
from ISO 10218-1
ISO/TS 15066 Robots and robotic devices - Collaborative robots
This Technical Specification specifies safety requirements for
collaborative industrial robot systems and the work environ-
ment, and supplements the requirements and guidance on
collaborative industrial robot operation given in ISO 10218-1
and ISO 10218-2.
Region specific standards and regulations
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require-
ments
EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus-
trial robots — Part 1: Robots

9.3 Unit conversion
9.3 Unit conversion
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

9.4 Screw joints
9.4 Screw joints
General
This section describes how to tighten the various types of screw joints on ABB
robots.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.
Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the
screw joint. It is recommended by ABB for M6-M20 screw joints. Screws treated
with Gleitmo may be reused 3-4 times before the coating disappears. After this the
screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.
Generally, screws are lubricated with Gleitmo 603 mixed with Geomet 500 or
Geomet 702 in proportion 1:3. Geomet thickness varies according to screw
dimensions, refer to the following.
Dimension Lubricant Geomet thickness
M6-M20 (any length except Gleitmo 603 + Geomet 500 3-5 μm
M20x60)
M6-M20 (any length except Gleitmo 603 + Geomet 720 3-5 μm
M20x60)
M20x60 Gleitmo 603 + Geomet 500 8-12 μm
M20x60 Gleitmo 603 + Geomet 720 6-10 μm
Screws lubricated in other ways

Screws lubricated with Molykote 1000 or Molykote P1900 should only be used
when specified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.

9.4 Screw joints
Continued
Lubricant Article number

Molykote 1000 (molybdenum disulphide grease) 3HAC042472-001
Molykote P1900 (molybdenum disulphide grease) 3HAC070875-001
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. 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.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Tightening torque for oil-lubricated screws with slotted or cross-recess head screws
The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Tightening torque for oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670

9.4 Screw joints
Continued
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M24 680 960 1150
Tightening torque for lubricated screws (Molykote, Gleitmo or equivalent) with allen head screws
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M5 8
M6 14
M8 28 35
M10 55 70
M12 96 120
M16 235 300
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

9.5 Weight specifications
9.5 Weight specifications
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.
Example
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.

9.6 Standard toolkit
9.6 Standard toolkit
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
Contents, standard toolkit
Qty Tool Rem.

1 Socket head cap 2-17 mm
1 Torque wrench 0.3-45 Nm
1 Torque wrench 50 Nm±5 Nm For securing robot to
foundation.
1 Ratchet head for torque wrench 1/2
1 Hex socket head cap no. 2.5 socket 1/2" bit L=110 mm
1 Small screwdriver
1 T-handle with ball head
1 Small cutting plier
1 Plastic mallet
1 Needle-nose plier

9.7 Special tools
9.7 Special tools
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard toolkit on page 712, and of special tools, listed directly in the instructions
and also gathered in this section.
Special tools
Note
If the replacing procedure is not listed in the table below, only standard tools are
needed for the procedure.
Tools and equipment with spare part number:

(These tools can be ordered from ABB)
- 24 VDC power supply
3HAC074119-001 Calibration tool box, Axis Calibration
Delivered as a set of calibration tools.
Required if Axis Calibration is the valid calibration
method for the robot.
The tool box also includes a unique calibration pin for
CRB 1100 to be fitted to the tool flange during calibration
of axis 6.
- Sonic tension meter
Used for measuring the timing belt tension.
- Dynamometer
Used for measuring the timing belt tension.
3HAC071022-001 Special toolkit
Includes J5.C2 connector assembly tool, brake release
button assembly tool, axis-4 motor fitting tool and M3x25
eye bolt.

10 Spare parts
10.1 Spare part lists and illustrations
10 Spare parts
10.1 Spare part lists and illustrations
Location
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.abb.com/myABB.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.

Index
Index connecting the robot and controller, cabling, 89

copper
disposal, 702
A
Absolute Accuracy, calibration, 653 D
allergenic material, 28 damaged bearings, 686
aluminum dimensions
disposal, 702 robot, 67
ambient humidity direction of axes, 656
operation, 41 Dual PROFIsafe-based laser scanner
storage, 41 laser scanner, 81–82, 133, 141
ambient temperature Dual SafetyIO-based laser scanner
operation, 41 laser scanner, 83, 150
storage, 41
assembly instructions, 49 E
assessment of hazards and risks, 28 environmental information, 702
Axis Calibration, 661 equipment, robot, 67
calibration tool ESD
article number, 664, 669 damage elimination, 48
examining, 664 sensitive equipment, 48
installation position, 666 expected life, 171
overview of method, 661 extender unit
procedure on FlexPendant, 669, 677 replacing, 437
protective cover and protection plug, 666, 669 extra equipment, 67
B F
base factory settings for SafeMove, 108
replacing, 281 faulty brake, 687
batteries fire extinguishing, 29
disposal, 702 fitting, equipment, 67
battery pack FlexPendant
replacing, 182 jogging to calibration position, 681
Brake power supply, faulty, 687 MoveAbsJ instruction, 681
brake releasing, 59 updating revolution counters, 660
brakes FlexPendant application, 107
testing function, 34 floor plan, 116
foundation
C requirements, 40
cabinet lock, 28
cable package G
lubricating, 180 gearbox, axis-4
cable package, lower replacing, 619
replacing, 239 gearbox, axis-3
cable package, upper replacing, 604
replacing, 196 gearbox, axis-2
cabling between robot and controller, 89 replacing, 587
calibrating gearbox, axis-1
robot, 661 replacing, 546
roughly, 657 Global Settings
calibrating robot, 661, 677 FlexPendant application, 107
calibration Gravity Alpha, 62
Absolute Accuracy type, 652 Gravity Beta, 61
rough, 657 grease, 31
standard type, 652 disposal, 702
verification, 679
when to calibrate, 654 H
calibration, Absolute Accuracy, 653 hanging
calibration manuals, 653 installed hanging, 28
calibration marks, 655 hazard levels, 19
calibration position hazardous material, 702
jogging to, 681 height
scales, 655 installed at a height, 28
calibration scales, 655 hot gearbox oil, 685–686
CalibWare, 652 hot surfaces, 31
carbon dioxide extinguisher, 29 housing
cleaning, 172 replacing, 395
Cold environments, 95 HRA, 28

Index
humidity replacing, 504

operation, 41 motor, axis-2
storage, 41 replacing, 492
motor, axis-1
I replacing, 477
information labels location, 173 mounting, equipment, 67
inspecting MoveAbsJ instruction, 681
information labels, 173
robot cabling, 175 N
timing belts, 176 national regulations, 28
installation negative directions, axes, 656
equipment, 67 neodymium
laser scanner, 79 disposal, 702
lead-through device, 72 network security, 16
instructions for assembly, 49 noise, 686
integrator responsibility, 28
intervals for maintenance, 169 O
oil, 31
L disposal, 702
labels oil leaks, 685
robot, 21 operating conditions, 41
Lamp indicator original spare parts, 17
safety configurations, 160 overfilled gearbox, 685
laser scanner
installation, 79 P
Laser scanner pedestal
dual PROFIsafe-based laser scanner, 81–82 installed on pedestal, 28
RobotWare 7.6 or later, 133, 141 personnel
Dual SafetyIO-based laser scanner, 83, 150 requirements, 18
PROFINET-based laser scanner, 123 plastic
PROFIsafe-based laser scanner, 80–81 disposal, 702
RobotWare 7.10 or later, 137 positive directions, axes, 656
RobotWare 7.6 or later, 129 PPE, 18
SafetyIO-based laser scanner, 82, 145 product standards, 706
lead PROFINET-based laser scanner
disposal, 702 laser scanner, 123
lead-through device PROFIsafe-based laser scanner
installation, 72 laser scanner, 80–81, 129, 137
leaking sealing, 685 protection classes, 41
lifting protection type, 41
robot, 54 protective equipment, 18
lifting accessory, 711 protective wear, 18
limitation of liability, 17
Lithium R
disposal, 702 recycling, 702
loads on foundation, 38 regional regulations, 28
lock and tag, 28 release brakes, 33
locked configuration file, 116 replacements, report, 189
lower arm replacing
replacing, 365 base, 281
lubricants, 31 battery pack, 182
lubricating cable package
cable package, 180 lower, 239
upper, 196
M extender unit, 437
maintenance intervals, 169 gearbox
maintenance schedule, 169 axis-4, 619
mechanical stop axis-3, 604
axis 1, 88 axis-2, 587
mechanical stop location, 88 axis-1, 546
motor, axis-6 housing, 395
replacing, 536 lower arm, 365
motor, axis-5 mechanical stop
replacing, 526 axis 1, 88
motor, axis-4 motor
replacing, 515 axis-6, 536
motor, axis-3 axis-5, 526

Index
axis-4, 515 speed

axis-3, 504 adjusting, 95
axis-2, 492 Speed control
axis-1, 477 safety configurations, 161–162
SMB unit, 273 strategies, 155
swing, 322 stability, 51
wrist, 437 standards, 706
report replacements, 189 ANSI, 706
requirements on foundation, 40 CAN, 706
responsibility and validity, 17 start of robot in cold environments, 95
revolution counters steel
storing on FlexPendant, 660 disposal, 702
updating, 657 storage conditions, 41
risk of burns, 31 suspended mounting, 61
risk of tipping, 51 swing
robot replacing, 322
dimensions, 67 symbols
equipment, fitting, 67 safety, 19
labels, 21 Synchronization
lifting, 54 FlexPendant application, 107
protection class, 41 synchronization position, 657
protection types, 41 sync marks, 655
symbols, 21 system integrator requirements, 28
technical data, 38 system parameter
working range, 45 Gravity Alpha, 62
robot cabling Gravity Beta, 61
inspecting, 175
Robot Encapsulation T
FlexPendant application, 107 technical data
rubber robot, 38
disposal, 702 temperatures
operation, 41
S storage, 41
SafeMove application, 107 template configurations for SafeMove, 108
safety Template SafeMove configuration file
brake testing, 34 safety configurations, 161–162, 164
ESD, 48 testing
fire extinguishing, 29 brakes, 34
release robot axes, 33 timing belts
signals, 19 inspecting, 176
signals in manual, 19 Tool Data
symbols, 19 FlexPendant application, 107
symbols on robot, 21 Tool Encapsulation
test run, 165 FlexPendant application, 107
safety configuration report, 116 torques on foundation, 38
Safety configurations transportation, 701
lamp indicator, 160 troubleshooting
speed control, 160 safety, 35
template SafeMove configuration file, 160 turning radius, 47
safety devices, 29
SafetyIO-based laser scanner U
laser scanner, 82, 145 upcycling, 702
safety signals updating revolution counters, 657
in manual, 19 users
safety standards, 706 requirements, 18
Safe Zones
FlexPendant application, 107 V
scales on robot, 655 validated configuration file, 116
schedule of maintenance, 169 validity and responsibility, 17
screw joints, 708 velocity
securing, robot, 57 adjusting, 95
securing the robot to foundation, attachment screws, 57 verifying calibration, 679
shipping, 701
signals W
safety, 19 wall mounting, 61
SMB unit weight, 38
replacing, 273 robot, 57

Index
working range, 47 overview of method, 677

robot, 45
wrist Z
replacing, 437 zero position
Wrist Optimization checking, 680

ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 10-732 50 00
ABB AS
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong New District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC078007-001, Rev M, en


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ROBOTICS

Document ID: 3HAC078007-001

© Copyright 2021-2024 ABB. All rights reserved.

© Copyright 2021-2024 ABB. All rights reserved.

3 Installation and commissioning 49

Product manual - CRB 1100 5

3.7.3 Lead-through .......................................................................................... 100

6 Product manual - CRB 1100

5.7 Motors ............................................................................................................ 477

9 Reference information 705

Product manual - CRB 1100 7

9.2 Applicable standards ......................................................................................... 706

10 Spare parts 715

8 Product manual - CRB 1100

Overview of this manual

It is the responsibility of the integrator to conduct a risk assessment of the final

Who should read this manual?

Product manual scope

Continues on next page

Continues on next page

Continues on next page

12 Product manual - CRB 1100

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

Technical reference manuals

Continues on next page

• Examples of how to use the application.

14 Product manual - CRB 1100

How to read the product manual

Product manual - CRB 1100 15

16 Product manual - CRB 1100

1.1.1 Limitation of liability

Spare parts and equipment

Product manual - CRB 1100 17

1.1.2 Requirements on personnel

Personal protective equipment

18 Product manual - CRB 1100

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

WARNING Signal word used to indicate a potentially hazardous

ELECTRICAL Signal word used to indicate a potentially hazardous

CAUTION Signal word used to indicate a potentially hazardous

ELECTROSTATIC Signal word used to indicate a potentially hazardous

NOTE Signal word used to indicate important facts and

Continues on next page

Symbol Designation Significance

20 Product manual - CRB 1100

1.2.2 Safety symbols on manipulator labels

Symbols on safety labels

Continues on next page

Before disassembly, see product manual

Continues on next page

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Continues on next page

Adjustable chain sling with shortener

Continues on next page

Shut off with handle

26 Product manual - CRB 1100

1.3 Robot stopping functions

Protective stop and emergency stop