ABB IRB 4600 - 40/2.55 Bedienungsanleitung

ABB Robotics

Product manual

IRB 4600

Trace back information:

Workspace R13-2 version a3

Checked in 2013-10-15

Skribenta version 4.0.378

Product manual

IRB 4600 - 60/2.05

IRB 4600 - 45/2.05

IRB 4600 - 40/2.55

IRB 4600 - 20/2.50

M2004

Document ID: 3HAC033453-001

Revision: H

The information in this manual is subject to change without notice and should not

be construed as a commitment by ABB. ABB assumes no responsibility for any errors

that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be

construed as any kind of guarantee or warranty by ABB for losses, damages to

persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from

use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's

written permission.

Additional copies of this manual may be obtained from ABB.

The original language for this publication is English. Any other languages that are

supplied have been translated from English.

ABB AB

Robotics Products

Se-721 68 Västerås

Sweden

Table of contents
9Overview of this manual ...................................................................................................................
16Product documentation, IRC5 ..........................................................................................................
18How to read the product manual ......................................................................................................
191 Safety
191.1 Introduction to safety information ......................................................................... 201.2 General safety information .................................................................................. 201.2.1 Introduction to general safety information .................................................... 211.2.2 Safety in the manipulator system ............................................................... 221.2.3 Safety risks ............................................................................................ 221.2.3.1 Safety risks during installation and service work on manipulators ......... 251.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 261.2.3.3 Safety risks related to tools/work pieces .......................................... 271.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 281.2.3.5 Safety risks with pressure relief valve .............................................. 291.2.3.6 Safety risks during operational disturbances ..................................... 301.2.3.7 Risks associated with live electric parts ........................................... 321.2.4 Safety actions ......................................................................................... 321.2.4.1 Safety fence dimensions ............................................................... 331.2.4.2 Fire extinguishing ........................................................................ 341.2.4.3 Emergency release of the manipulator’s arm .................................... 351.2.4.4 Brake testing .............................................................................. 361.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 371.2.4.6 Safe use of the FlexPendant .......................................................... 381.2.4.7 Work inside the manipulator's working range ................................... 391.2.4.8 Signal lamp (optional) ................................................................... 401.2.5 Safety stops ........................................................................................... 401.2.5.1 What is an emergency stop? .......................................................... 421.3 Safety related instructions .................................................................................. 421.3.1 Safety signals in the manual ...................................................................... 441.3.2 Safety symbols on manipulator labels ......................................................... 491.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 501.3.4 DANGER - First test run may cause injury or damage! ................................... 511.3.5 WARNING - The brake release buttons may be jammed after service work ........ 521.3.6 DANGER - Make sure that the main power has been switched off! .................... 531.3.7 WARNING - The unit is sensitive to ESD! ..................................................... 541.3.8 WARNING - Safety risks during handling of batteries ..................................... 551.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
572 Installation and commissioning
572.1 Introduction ...................................................................................................... 582.2 Unpacking ....................................................................................................... 582.2.1 Pre-installation procedure ......................................................................... 612.2.2 Working range and type of motion .............................................................. 652.2.3 Risk of tipping/stability ............................................................................. 662.3 On-site installation ............................................................................................ 662.3.1 Lifting robot with roundslings .................................................................... 692.3.2 Lifting and turning a suspended mounted robot ............................................ 702.3.3 Manually releasing the brakes ................................................................... 732.3.4 Orienting and securing the robot ................................................................ 762.3.5 Setting the system parameters for a suspended robot .................................... 782.3.6 Fitting equipment on robot ........................................................................ 842.3.7 Loads .................................................................................................... 852.3.8 Installation of signal lamp (option) .............................................................. 862.4 Restricting the working range .............................................................................. 862.4.1 Introduction ............................................................................................
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Table of contents

4.2 Mechanically restricting the working range of axis 1 ...................................... 902.5 Installing options ............................................................................................... 902.5.1 Installation of cooling fan for motors (option) ................................................ 972.5.2 Installation of Foundry Plus Cable guard (option no. 908-1) ............................. 982.5.3 Installing an expansion container ............................................................... 1002.6 Robot in hot environments .................................................................................. 1002.6.1 Start of robot in hot environments .............................................................. 1012.7 Robot in cold environments ................................................................................. 1012.7.1 Start of robot in cold environments ............................................................. 1022.8 Electrical connections ........................................................................................ 1022.8.1 Robot cabling and connection points .......................................................... 1042.8.2 Customer connection on robot ................................................................... 1062.8.3 Customer connections on upper arm ..........................................................
Maintenance
1 Introduction ...................................................................................................... 1103.2 Maintenance schedule ....................................................................................... 1103.2.1 Specification of maintenance intervals ........................................................ 1113.2.2 Maintenance schedule ............................................................................. 1133.2.3 Expected component life ......................................................................... 1143.3 Inspection activities ........................................................................................... 1143.3.1 Inspecting oil level, axis 1 gearbox ............................................................. 1213.3.2 Inspecting the oil level, axis 2 gearbox ........................................................ 1233.3.3 Inspecting the oil level, axis 3 gearbox ........................................................ 1263.3.4 Inspecting the oil level, axis 4 gearbox ........................................................ 1283.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................ 1323.3.6 Inspecting the cable harness ..................................................................... 1343.3.7 Inspecting information labels ..................................................................... 1373.3.8 Inspecting the mechanical stop pin, axis 1 ................................................... 1403.3.9 Inspecting additional mechanical stops ....................................................... 1423.3.10 Inspecting dampers ................................................................................. 1443.3.11 Inspecting the pressure relief valve ............................................................ 1463.3.12 Inspecting Signal lamp (option) .................................................................. 1483.4 Replacement activities ....................................................................................... 1483.4.1 Type of lubrication in gearboxes ................................................................ 1503.4.2 Changing the oil, axis-1 gearbox on floor mounted robots ............................... 1563.4.3 Changing the oil, axis-1 gearbox on suspended robots ................................... 1623.4.4 Changing the oil, axis-2 gearbox ................................................................ 1663.4.5 Changing the oil, axis-3 gearbox ................................................................ 1723.4.6 Changing the oil, axis-4 gearbox ................................................................ 1763.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................ 1823.4.8 Replacing SMB battery ............................................................................. 1873.5 Cleaning activities ............................................................................................. 1873.5.1 Cleaning, robot ......................................................................................
Repair
1 Introduction ...................................................................................................... 1904.2 General procedures ........................................................................................... 1904.2.1 Performing a leak-down test ...................................................................... 1914.2.2 Mounting instructions for bearings ............................................................. 1934.2.3 Mounting instructions for seals .................................................................. 1954.3 Complete robot ................................................................................................. 1954.3.1 Removing the complete cable harness ........................................................ 2074.3.2 Refitting the complete cable harness .......................................................... 2234.3.3 Replacing SMB unit ................................................................................. 2284.3.4 Replacing the brake release unit ................................................................ 2324.3.5 Replacing the base .................................................................................. 2424.4 Upper arm ....................................................................................................... 2424.4.1 Replacing the complete upper arm .............................................................
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© Copyright 2009-2013 ABB. All rights reserved.
Table of contents

4.2 Replacing complete tubular shaft unit ......................................................... 2574.4.3 Replacing wrist unit ................................................................................. 2624.4.4 Measuring the play, axis 5 ........................................................................ 2654.4.5 Measuring the play, axis 6 ......................................................................... 2684.5 Lower arm ....................................................................................................... 2684.5.1 Replacing the lower arm ........................................................................... 2754.6 Frame and base ................................................................................................ 2754.6.1 Replacing stop pin axis 1 .......................................................................... 2784.7 Motors ............................................................................................................ 2784.7.1 Removing motors .................................................................................... 2864.7.2 Refitting motors ...................................................................................... 2964.7.3 Adjusting the play of axis 4, 5 and 6 motors ................................................. 2974.8 Gearboxes ....................................................................................................... 2974.8.1 Replacing gearbox axis 1 .......................................................................... 3034.8.2 Replacing gearbox axis 2 .......................................................................... 3114.8.3 Replacing gearbox axis 3 ..........................................................................
Calibration
1 Introduction ..................................................................................................... 3205.2 Calibration methods ........................................................................................... 3225.3 Calibration scale and correct axis position ............................................................. 3255.4 Calibration movement directions for all axes .......................................................... 3265.5 Updating revolution counters ............................................................................... 3285.6 Checking the calibration position ..........................................................................
Decommissioning
1 Introduction ...................................................................................................... 3306.2 Environmental information ..................................................................................
Robot description
1 Type C of IRB 4600 ............................................................................................
Reference information
1 Introduction ...................................................................................................... 3348.2 Applicable safety standards ................................................................................ 3368.3 Unit conversion ................................................................................................. 3378.4 Screw joints .................................................................................................... 3408.5 Weight specifications ......................................................................................... 3418.6 Standard tools .................................................................................................. 3428.7 Special tools .................................................................................................... 3448.8 Lifting accessories and lifting instructions ..............................................................
Spare part list
1 Rebuilding parts ................................................................................................ 3479.2 Base cover assembly ......................................................................................... 3489.3 Base and frame unit ........................................................................................... 3509.4 Lower arm and frame ......................................................................................... 3529.5 Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 ............................................ 3589.6 Wrist unit (60 kg/45 kg/20 kg) .............................................................................. 3619.7 Electrical connections ........................................................................................ 3639.8 Gearboxes ....................................................................................................... 3659.9 Motors ............................................................................................................ 3679.10 Labels ............................................................................................................. 3689.11 Options ...........................................................................................................
Circuit diagram
1 About circuit diagrams .......................................................................................
3HAC033453-001 Revision: H 7
© Copyright 2009-2013 ABB. All rights reserved.
Table of contents

371Index

8 3HAC033453-001 Revision: H

Table of contents

Overview of this manual

About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot.

The robot described in this manual has the protection type Standard and Foundry

Plus.

Usage

This manual should be used during:

• installation, from lifting the robot to its work site and securing it to the

foundation, to making it ready for operation

• maintenance work

• repair work and calibration.

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.

Organization of chapters

The manual is organized in the following chapters:

ContentsChapter

Safety information that must be read through before performing

any installation or service work on the robot. Contains general

safety aspects as well as more specific information on how to

avoid personal injuries and damage to the product.

Safety

Required information about lifting and installation of the robot.Installation and commis-

sioning

Step-by-step procedures that describe how to perform mainten-

ance of the robot. Based on a maintenance schedule that may

be used to plan periodical maintenance.

Maintenance

Step-by-step procedures that describe how to perform repair

activities of the robot. Based on available spare parts.

Repair

Procedures that do not require specific calibration equipment.

General information about calibration.

Calibration information

Environmental information about the robot and its components.Decommissioning

Continues on next page

3HAC033453-001 Revision: H 9

Overview of this manual

ContentsChapter

Useful information when performing installation, maintenance

or repair work. Includes lists of necessary tools, additional doc-

uments, safety standards etc.

Reference information

Complete spare part list and complete list of robot components,

shown in exploded views.

Spare part / part list

Detailed illustrations of the robot with reference numbers to the

part list.

Exploded views

Reference to the circuit diagram for the robot..Circuit diagram

References

Document IdReference

3HAC040585-001Product manual - IRB 4600 Foundry Prime

3HAC032885-001Product specification - IRB 4600

3HAC029038-003Circuit diagram - IRB 4600

3HAC021313-001Product manual - IRC5

IRC5 with main computer DSQC 639.

3HAC047136-001Product manual - IRC5

IRC5 with main computer DSQC1000.

3HAC027098-001Operating manual - Emergency safety information

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC020738-001Operating manual - Trouble shooting IRC5

3HAC16578-1Operating manual - Calibration Pendulum

3HAC025709-001Operating manual - Service Information System

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC17076-1Technical reference manual - System parameters

3HAC021395-001Application manual - Additional axes and stand alone controller

3HAC027709-001Application manual - Electronic Position Switches

3HAC030421-001Application manual - CalibWare Field 5.0

Revisions

DescriptionRevision

First edition-

Continues on next page

10 3HAC033453-001 Revision: H

Overview of this manual

Continued

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