ABB M2004 is a versatile articulated robot designed for industrial automation tasks. With a handling capacity of up to 60 kg and a reach of 2.5 meters, it's ideal for various applications, including welding, assembly, and material handling. ABB M2004 is available in different versions, including Foundry and Foundry Prime models for harsh environments. Its open structure, extensive communication capabilities, and built-in process ware make it easy to integrate into automated systems.
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Product specification
Articulated robot
IRB 4400/45
IRB 4400/60
IRB 4400/L30
IRB 4400/L10
IRB 4450/S
M2004
Product specification
Articulated robot
3HAC9117-1
Rev.N
IRB 4400/45
IRB 4400/60
IRB 4400/L30
IRB 4400/L10
IRB 4450/S
M2004
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2004 ABB All right reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of Contents
2 Specification of Variants and Options 53
3HAC9117-1 Rev.N
3
Table of Contents
4 Rev.N
3HAC9117-1
Overview
Overview
About this Product specification
It describes the performance of the manipulator or a complete family of manipulators in terms of:
• The structure and dimensional prints
• The fulfilment of standards, safety and operating requirements
• The load diagrams, mounting of extra equipment, the motion and the robot reach
• The specification of variant and options available
Users
It is intended for:
• Product managers and Product personnel
• Sales and Marketing personnel
• Order and Customer Service personnel
Contents
Please see Table of Contents on page 3.
Revisions
Revision
Revision 8
Revision J
Revision K
Revision L
Revision M
Revision N
Description
- New values for Performance Acc. to ISO 9283 added
- M2000 cancelled.
- Foundry Prime added
- Option 287-5 Wash removed
- Text added to “Clean room robots”
- Footnote added to “Pose accuracy”
- Changes in chapter Standards
- Directions of forces
- Warranty information for load diagrams
- Maximum load and moment of inertia for full axis 5 movement
- Wrist torque
- Changes for Calibration data
- Work range
- Explanation of ISO values (new figure and table)
- Stopping distance
- User documentation on DVD
3HAC9117-1 Rev.N
5
Overview
Complementary Product specifications
Product specification
Controller
Controller Software
IRC5
Robot User Documentation
Description
IRC5 with FlexPendant, 3HAC021785-001
RobotWare 5.11, 3HAC022349-001
IRC5 and M2004, 3HAC024534-001
6 Rev.N
3HAC9117-1
1 Description
1.1.1 Introduction
1 Description
1.1 Structure
1.1.1 Introduction
General
Different versions
The IRB 4400 comes in several different versions, with handling capacities of up to 60 kg, a maximum reach of 2.5 m, floor or shelf-mounted manipulators as well as manipulators for harsh environments.
Foundry robots
The IRB 4400 is a 6-axis industrial robot, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has built-in process ware, an open structure that is specially adapted for flexible use, and can communicate extensively with external systems.
The robot version Foundry is suitable for operating in harsh environments and has special surface treatment and paint for excellent corrosion protection. The connectors are designed for severe environments, and bearings, gears and other sensitive parts are highly protected. The robots have the FoundryPlus protection which means that the whole manipulator is IP67 classified and steam washable.
Foundry Prime
3HAC9117-1
The robot version Foundry Prime is designed for water jet cleaning of casts and machined parts, and similar very harsh environments.
The manipulator can withstand surrounding solvent based detergent (max. pH 9.0 and must contain rust inhibitor). The detergent must be approved by ABB. In addition, the manipulator can withstand indirect spray from jet pressure (max. 600 bar) and 100% humidity. The manipulator can work in an environment with a cleaning bath temperature < 60 o
C, typically used in a water jet cleaning application with moderate speed.
The robot is protected by special sealings for gears and bearings, pressurized motors and electronic compartment, special detergent resistant polyurethane painting system in three layers. Non painted surfaces has a special rust preventive coating, and motors are sealed with a sealing compound.
As the robot is designed for very harsh environments, an extended service and maintenance program is required. For detailed information of the maintenance program, see chapter Maintenance in the Product Manual.
The protection, Foundry Prime is only available for robot version IRB 4400/60.
See chapter Specification of Variants and Options for options not selectable together with Foundry Prime.
Rev.N
7
1 Description
1.1.1 Introduction
Clean Room robots
The Clean Room robots are classified for clean room class 100 according to US
Federal Standard 209 or class 5 according to ISO 14644-1.
The performed clean room test has classify the air cleanliness exclusively in terms of concentration of airborne particles generated by the robot. Other aspects of the clean room test or other clean room requirements are not considered.
Operating system
The robot is equipped with the IRC5 controller and robot control software,
RobotWare.
RobotWare supports every aspect of the robot system, such as motion control, development and execution of application programs, communication etc. See
Product specification - Controller IRC5 with FlexPendant.
Safety standards require a controller to be connected to the robot.
For additional functionality, the robot can be equipped with optional software for application support - for example gluing and arc welding, communication features - network communication - and advanced functions such as multitasking, sensor control etc. For a complete description on optional software, see the Product specification - Controller software IRC5/RobotWare.
8
Figure 1 The IRB 4400 manipulator has 6 axes.
Rev.N
3HAC9117-1
1 Description
1.1.2 Different robot versions
1.1.2 Different robot versions
General
The IRB 4400 is available in five different versions.
Robot type
IRB 4400/45
IRB 4400/60
IRB 4400/L30
IRB 4400/L10
IRB 4450S
Handling capacity (kg) Reach (m)
45 kg
60 kg
30 kg
10 kg
30 kg
1.96 m
1.96 m
2.43 m
2.55 m
2.40 m
1.1.3 Definition of version designation
IRB 4400 Version Handling capacity:
Prefix description
Version
Handling capacity
L
S
Robot type
Description
Long arm
Shelf mounted manipulator
Indicates the maximum handling capacity (kg)
Manipulator weight
Other technical data
Robot type
IRB 4400/45
IRB 4400/60
IRB 4400/L10
IRB 4400/L30
IRB 4450/S
Weight
985 kg
1040 kg
1040 kg
1060 kg
1040 kg
Data Description Note
Airborne noise level The sound pressure level outside the working space
< 70 dB (A) Leq (acc. to Machinery directive 89/392 EEC)
3HAC9117-1 Rev.N
9
1 Description
1.1.3 Definition of version designation
Power consumption
Path E1-E2-E3-E4 in the ISO Cube, maximum load.
IRB 4400/45 (Cube side = 630 mm)
Speed [mm/s]
Max.
1000
500
100
Power consumption [kW]
1.36
0.95
0.74
0.62
IRB 4400/60 (Cube side = 630 mm)
Speed [mm/s]
Max.
1000
500
100
Power consumption [kW]
1.33
0.99
0.78
0.66
10
Figure 2 Path E1-E2-E3-E4 in the ISO Cube, maximum load.
Rev.N
3HAC9117-1
IRB 4400/L30 (Cube side = 1000 mm)
Speed [mm/s]
Max.
1000
500
100
Power consumption [kW]
1.15
0.86
0.73
0.64
IRB 4400/L10 (Cube side = 1000 mm)
Speed [mm/s]
Max.
1000
500
100
Power consumption [kW]
1.28
0.63
0.53
0.48
1 Description
1.1.3 Definition of version designation
3HAC9117-1
Figure 3 Path E1-E2-E3-E4 in the ISO Cube, maximum load.
IRB 4450/S (Cube side = 1000 mm)
Speed [mm/s]
Max.
1000
500
100
Power consumption [kW]
Not yet available
Not yet available
Not yet available
Not yet available
Rev.N
11
1 Description
1.1.3 Definition of version designation
Dimensions
IRB 4400/45, IRB 4400/60, IRB 4400/L30:
12
Figure 4 View of the manipulator from the side (dimensions in mm).
Pos
A
B
Description
880 for 4400/45 and /60
1380 for 4400/L30
Rev.N
3HAC9117-1
1 Description
1.1.3 Definition of version designation
Figure 5 View of the manipulator from the side (dimensions in mm).
IRB 4400/45, IRB 4400/60 and IRB 4400/L30:
3HAC9117-1
Figure 6 View of the manipulator from above (dimensions in mm).
Rev.N
13
1 Description
1.1.3 Definition of version designation
IRB 4400/L10:
Figure 7 View of the manipulator from the side and above (dimensions in mm).
14 Rev.N
3HAC9117-1
IRB 4450/S:
1 Description
1.1.3 Definition of version designation
Figure 8 View of the manipulator from the side, behind and above (dimensions in mm).
3HAC9117-1 Rev.N
15
1 Description
1.2.1 Standards
1.2 Safety/Standards
1.2.1 Standards
The robot conforms to the following standards:
Standard
EN ISO 12100-1
EN ISO 12100-2
EN 954-1
EN 60204
EN ISO 60204-1:2006
EN ISO 10218-1:2006 a
EN 61000-6-4 (option)
EN 61000-6-2
Description
Safety of machinery, terminology
Safety of machinery, technical specifications
Safety of machinery, safety related parts of control systems
Electrical equipment of industrial machines
Safety of machinery - Electrical equipment of machines
Robots for industrial environments - Safety requirements
EMC, Generic emission
EMC, Generic immunity a. There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times are documented.
Standard
IEC 60529
Standard
ISO 9787
Description
Degrees of protection provided by enclosures
Description
Manipulating industrial robots, coordinate systems and motions
Standard
ANSI/RIA 15.06/1999
ANSI/UL 1740-1998
(option)
CAN/CSA Z 434-03
(option)
Description
Safety Requirements for Industrial Robots and Robot Systems
Safety Standard for Robots and Robotic Equipment
Industrial Robots and Robot Systems - General Safety Requirements
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
16 Rev.N
3HAC9117-1
1 Description
1.2.2 Safety
1.2.2 Safety
The robot is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the FlexPendant, that is not by any external equipment.
Reduced speed
Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery - safety related parts of control systems - Part 1.
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Center Point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the FlexPendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the
FlexPendant to find the right key.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the
FlexPendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit.
3HAC9117-1 Rev.N
17
1 Description
1.2.2 Safety
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal program stop with no deviation from the programmed path. After approx. 1 second the power supplied to the motors shuts off.
Collision detection (option)
In case of an unexpected mechanical disturbance like a collision, electrode sticking etc., the robot will stop and slightly back off from its stop position.
Restricting the working space
The movement of each axis can be restricted using software limits.
Axes 1-2 can also be restricted by means of mechanical stops and axis 3 by an electrical switch (option).
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order to move the robot. When the button is released the robot will stop. The hold-to-run function makes program testing safer.
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters
Laboratories) tough requirements for fire safety.
Safety lamp (option)
The robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.
18 Rev.N
3HAC9117-1
1 Description
1.3.1 Introduction
1.3 Installation
1.3.1 Introduction
General
All the versions of IRB 4400 are designed for floor mounting except one version for shelf-mounting. Depending on the robot version an end effector of max. weight
10 to 60 kg, including payload, can be mounted on the mounting flange (axis 6). See
Other equipment
Extra loads can be mounted on the upper arm and on the base.
There are holes for mounting extra equipment, see section Mounting equipment ,
Working range
The working range of axes 1-2 can be limited by mechanical stops and axis 3 by limit switches. Electronic Position Switches can be used on all axes for indicating the position of the manipulator.
3HAC9117-1 Rev.N
19
1 Description
1.3.2 Operating requirements
1.3.2 Operating requirements
Protection standards
Description
Standard and Clean Room Manipulator
Foundry Manipulator
Protection standard IEC 60529
IP54
IP67, steam washable
Clean room standards
Clean room manipulator: US Federal Standard 209, class 100 or ISO 14644-1 class 5.
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Description
Manipulator during operation
For the controller
Standard/Option
Standard
Standard/Option
Complete robot during transportation and storage
For short periods (not exceeding 24 hours)
Standard
Standard
Temperature
+ 5°C (41°F) to + 45°C (113°F)
See Product specification - Controller IRC5 with FlexPendant
- 25°C (-13°F) to + 55°C (131°F) up to + 70°C (158°F)
Relative humidity
Description
Complete robot during transportation and storage
Complete robot during operation
Complete robot during operation, option 287-6
Foundry Prime
Relative humidity
Max. 95% at constant temperature
Max. 95% at constant temperature
Max. 100%
20 Rev.N
3HAC9117-1
1 Description
1.3.3 Mounting the manipulator
1.3.3 Mounting the manipulator
Maximum load in relation to the base coordinate system.
Force xy
Force z
Torque xy
Torque z
Endurance load in operation all IRB 4400
± 7500 N
+ 9500 ± 2000 N
± 14000 Nm
± 2000 Nm
Max. load at emergency stop all IRB 4400
± 9000 N
+ 9500 ± 3000 N
± 16000 Nm
± 4000 Nm
Force xy
Force z
Torque xy
Torque z
Endurance load in operation all IRB 4450/S
± 7500 N
+ 9500 ± 2000 N
± 14000 Nm
± 2000 Nm
Max. load at emergency stop all IRB 4450/S
± 10000 N
+ 9500 ± 4000 N
± 16000 Nm
± 4000 Nm
3HAC9117-1 Rev.N
21
1 Description
1.3.3 Mounting the manipulator
Figure 9 Direction of forces.
Note regarding M xy
and F xy
The bending torque (M xy
) can occur in any direction in the XY-plane of the base coordinate system.
The same applies to the transverse force (F xy
).
22 Rev.N
3HAC9117-1
Figure 10 Hole configuration (dimensions in mm).
Pos
C
D
A
B
Description
Z = center line axis 1
The same dimensions
View from the bottom of the base
Section
1 Description
1.3.3 Mounting the manipulator
3HAC9117-1 Rev.N
23
1 Description
1.3.3 Mounting the manipulator
Mounting surface and bushings
24
Figure 11 Mounting surface and bushings.
Pos
A
B
Description
Surface treatment, ISO 2081 Fe/Zn 8 c2
Guide Bushings
Common zone
Rev.N
3HAC9117-1
1 Description
1.4.1 Fine calibration
1.4 Calibration and References
1.4.1 Fine calibration
General
Fine calibration is made using the Calibration Pendulum, please see Operating manual - Calibration Pendulum.
Figure 12 All axes in zero position.
Calibration
Calibration of all axes
Calibration of axis 1 and 2
Calibration of axis 1
Position
All axes are in zero position
Axis 1 and 2 in zero position
Axis 3 to 6 in any position
Axis 1 in zero position
Axis 2 to 6 in any position
3HAC9117-1 Rev.N
25
1 Description
1.4.2 Absolute Accuracy calibration
1.4.2 Absolute Accuracy calibration
General
The calibration concept
Absolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute accuracy of better than ±1 mm in the entire working range.
Absolute accuracy compensates for:
• Mechanical tolerances in the robot structure
• Deflection due to load
Absolute accuracy calibration focuses on positioning accuracy in the cartesian coordinate system for the robot. It also includes load compensation for deflection caused by the tool and equipment. Tool data from robot program is used for this purpose. The positioning will be within specified performance regardless of load.
Calibration data
Requires RobotWare option Absolute Accuracy, please see Product specification -
Controller software IRC5/RobotWare for more details.
The user is supplied with robot calibration data (compensation parameters saved on the manipulator SMB) and a certificate that shows the performance (Birth certificate). The difference between an ideal robot and a real robot without AbsAcc can typically be 8 mm, resulting from mechanical tolerances and deflection in the robot structure.
If there is a difference, at first start-up, between calibration data in controller and the robot SMB, correct by copying data from SMB to controller.
26 Rev.N
3HAC9117-1
1 Description
1.4.2 Absolute Accuracy calibration
Absolute Accuracy option
Absolute Accuracy option is integrated in the controller algorithms for compensation of this difference and does not need external equipment or calculation.
Absolute Accuracy is a RobotWare option and includes an individual calibration of the robot (mechanical arm).
Absolute Accuracy is a TCP calibration in order to Reach (m) a good positioning in the Cartesian coordinate system.
Figure 13 The Cartesian coordinate system.
Production data
Typical production data regarding calibration are:
Positioning accuracy (mm)
Robot
Average Max % Within 1 mm
IRB 4400/45, -/60,
-/L30 and -/L10
IRB 4450/S
0.30
a
0.75
a
100 a a. For detailed data and data missing in the table, please contact ABB for more information.
3HAC9117-1 Rev.N
27
1 Description
1.5.1 Introduction
1.5 Load diagrams
1.5.1 Introduction
It is very important to always define correct actual load data and correct payload of the robot. Incorrect definitions of load data can result in overloading of the robot.
If incorrect load data and/or loads outside load diagram is used the following parts can be damaged due to overload:
• motors
• gearboxes
• mechanical structure
Robots running with incorrect load data and/or with loads outside load diagram will not be covered by the robot warranty.
28 Rev.N
3HAC9117-1
1.5.2 Diagrams
IRB 4400/45
1 Description
1.5.2 Diagrams
3HAC9117-1
Z
L
J
Figure 14 Maximum weight permitted for load mounted on the mounting flange at different positions
(center of gravity).
Description
See the above diagram and the coordinate system in the Product specification
- IRC5 with FlexPendant.
Distance in X-Y plane from Z-axis to the center of gravity.
Maximum own moment of inertia on the total handle weight = max. 2.5 kgm
2
.
Rev.N
29
1 Description
1.5.2 Diagrams
IRB 4400/60
30
Z
L
J
Figure 15 Maximum weight permitted for load mounted on the mounting flange at different positions
(center of gravity).
Description
See the above diagram and the coordinate system in the Product specification
- IRC5 with FlexPendant.
Distance in X-Y plane from Z-axis to the center of gravity.
Maximum own moment of inertia on the total handle weight = max. 2.5 kgm
2
.
Rev.N
3HAC9117-1
IRB 4400/L30 and IRB 4450/S
1 Description
1.5.2 Diagrams
3HAC9117-1
Z
L
J
Figure 16 Maximum weight permitted for load mounted on the mounting flange at different positions
(center of gravity).
Description
See the above diagram and the coordinate system in the Product specification
- IRC5 with FlexPendant.
Distance in X-Y plane from Z-axis to the center of gravity.
Maximum own moment of inertia on the total handle weight = max. 1.3 kgm
2
.
Rev.N
31
1 Description
1.5.2 Diagrams
IRB 4400/L10
32
Z
L
J
Figure 17 Maximum weight permitted for load mounted on the mounting flange at different positions
(center of gravity).
Description
See the above diagram and the coordinate system in the Product specification
- IRC5 with FlexPendant.
Distance in X-Y plane from Z-axis to the center of gravity.
Maximum own moment of inertia on the total handle weight = max.
≤ 0.040
kgm
2
.
Rev.N
3HAC9117-1
1 Description
1.5.3 Maximum load and moment of inertia for full axis 5 movement
1.5.3 Maximum load and moment of inertia for full axis 5 movement
General
Total load given as: Mass in kg, center of gravity (Z and L) in meter and moment of inertia (J ox
, J oy
, J oz
) in kgm
2
. L=
√(
X
2
+ Y
2
Full movement of Axis 5 (±120º)
5
Axis Robot Type Max. value
5
6
IRB 4400/L10
IRB 4400/L10
J
5
= Mass x ((Z + 0.085)
2
+ L
2
) + max (J
0x
, J
0y
)
≤
1.15 kgm
2
J
6
= Mass x L
2
+ J
0Z
≤
0.70 kgm
2
Axis Robot Type
5
6
IRB 4400/L30,
IRB 4450S
IRB 4400/L30,
IRB 4450S
Max. value
J
5
= Mass x ((Z + 0.14)
2
+ L
2
) + max (J
0x
, J
0y
)
≤
22.0 kgm
2
J
6
= Mass x L
2
+ J
0Z
≤
12.0 kgm
2
Axis Robot Type
5
6
IRB 4400/45
IRB 4400/45
Max. value
J
5
= Mass x ((Z + 0.14)
2
+ L
2
) + max (J
0x
, J
0y
)
≤
25.0 kgm
2
J
6
= Mass x L
2
+ J
0Z
≤
16.5 kgm
2
Axis Robot Type
5
6
IRB 4400/60
IRB 4400/60
Max. value
J
5
= Mass x ((Z + 0.14)
2
+ L
2
) + max (J
0x
, J
0y
)
≤
30.0 kgm
2
J
6
= Mass x L
2
+ J
0Z
≤
17.5 kgm
2
3HAC9117-1
Figure 18 Moment of inertia when full movement of axis 5.
Pos
A
Description
Center of gravity
J ox
, J oy
, J oz
Description
Max. moment of inertia around the X, Y and Z axes at center of gravity.
Rev.N
33
1 Description
1.5.4 Wrist torque
1.5.4 Wrist torque
The table below shows the maximum permissible torque due to payload.
.
Note! The values are for reference only, and should not be used for calculating permitted load offset (position of center of gravity) within the load diagram, since those also are limited by main axes torques as well as dynamic loads. Also arm loads will influence the permitted load diagram. For finding the absolute limits of the load diagram, please contact your local ABB organization
.
Robot type
IRB 4400/L10
RB 4400/L30, IRB 4450S
IRB 4400/45
IRB 4400/60
Max wrist torque axis 4 and 5
Max wrist torque axis 6
Max torque valid at load
20.6 Nm
155.0 Nm
190.0 Nm
242.0 Nm
9.81 Nm
63.3 Nm
75.0 Nm
98.9 Nm
10 kg
30 kg
45 kg
60 kg
34 Rev.N
3HAC9117-1
1 Description
1.6.1 Introduction
1.6 Mounting equipment
1.6.1 Introduction
IRB 4400/45, IRB 4400/60, IRB 4400/L30 and IRB 4450/S
A
250
175
(A)
D
(B)
D 25 50
B - B
15
Max. 15 kg
144
340
(C)
D - D
29.5
29.5
(D)
200
106
A - A
(E)
(F)
150
A
300
115 54
20 o
110
390
150
B
B
195
C
D=100
(G)
15 o
120 o
(3x)
3HAC9117-1
C
C - C
Figure 19 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).
Pos
A
B
Description
M8 (2x) Used if option 218-6 is chosen, Depth of thread 9
M8 (3x) Depth of thread 14
Rev.N
35
1 Description
1.6.1 Introduction
D
E
Pos
C
F
G
Description
571 for 4400/45, /60 and 4450S
1071 for 4400L/30
M6 (2x) tapped depth 12
Max. 5 kg for 4400/45 and /60 at max. handling weight
5 kg for 4400L/30 and 4450S if handling weight is max. 25 kg,
0 kg if handling weight is 30 kg
M8 (3x), R = 92, Depth 16 (If option 34-1 is chosen these holes are occupied.)
Max. 35 kg
36 Rev.N
3HAC9117-1
1 Description
1.6.1 Introduction
IRB 4400/L10
250
175
A
(A)
(B)
B - B
Max. 15 kg
110
M5 (2x)
1221
300
150
A
300
390
B
115
54
20 o
150
B
D=240 22
78
A - A
43
(C)
Max. 2 kg
110
195
C
D=100
Max. 35 kg
15 o
120 o
(3x)
C
C - C
Figure 20 The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes (dimensions in mm).
Pos
A
B
E
Description
M6 (2x) Depth of thread 9
M8 (3x) Depth of thread 14
M8 (3x), R=92 Depth 16
(If option 34-1 is chosen these holes are occupied.)
3HAC9117-1 Rev.N
37
1 Description
1.6.2 Robot tool flange
1.6.2 Robot tool flange
IRB 4400/45, IRB 4400/60, IRB 4400/L30 and IRB 4450/S
IRB 4400/L10
Figure 21 The mechanical interface, mounting flange (dimensions in mm).
38
Figure 22 The mechanical interface, mounting flange (dimensions in mm).
Rev.N
3HAC9117-1
1 Description
1.7.1 Introduction
1.7 Maintenance and Troubleshooting
1.7.1 Introduction
General
The robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible:
• Maintenance-free AC motors are used
• Oil is used for the gear boxes
• The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change
Maintenance
The maintenance intervals depend on the use of the robot, the required maintenance activities also depend on selected options. For detailed information on maintenance procedures, see Maintenance section in the Product Manual.
3HAC9117-1 Rev.N
39
1 Description
1.8.1 Introduction
1.8 Robot Motion
1.8.1 Introduction
IRB 4400/45 and IRB 4400/60
Type of motion
Axis 1 Rotation motion
Axis 2 Arm motion
Axis 3 Arm motion
Axis 4 Wrist motion
Axis 5 Bend motion
Axis 6 Turn motion
Range of movement
+ 165° to - 165°
+ 95° to - 70°
+ 65° to - 60°
+ 200° to - 200°
+ 120° to - 120°
+ 400° to - 400°
+200 rev.
a
to -200 rev. Max.
b a. rev. = Revolutions b. The default working range for axis 6 can be extended by changing parameter values in the software.
Option 610-1 “Independent axis” can be used for resetting the revolution counter after the axis has been rotated (no need for “rewinding” the axis).
40 Rev.N
3HAC9117-1
1 Description
1.8.1 Introduction
3HAC9117-1
Figure 23 The extreme positions of the robot arm IRB 4400/45 and /60 (dimensions in mm).
Positions (mm) and Angles (degrees) for IRB 4400/45 and IRB 4400/60:
5
6
3
4
0
1
2
Position No.
Position
(mm) X
1080
887
708
1894
570
51
227
Position
(mm) Z
1720
2140
836
221
-126
1554
1210
Angle
(degrees)
Axis 2
0
0
0
95
95
-70
-70
Angle
(degrees)
Axis 3
0
-30
65
-60
40
40
65
Rev.N
41
1 Description
1.8.1 Introduction
IRB 4400/L30
Type of motion
Axis 1 Rotation motion
Axis 2 Arm motion
Axis 3 Arm motion
Axis 4 Wrist motion
Axis 5 Bend motion
Axis 6 Turn motion
Range of movement
+ 165° to - 165°
+ 95° to - 70°
+ 65° to - 60°
+ 200° to - 200°
+ 120° to - 120°
+ 400° to - 400°
+200 rev.
a
to -200 rev. Max.
b a. rev. = Revolutions b. The default working range for axis 6 can be extended by changing parameter values in the software.
Option 610-1 “Independent axis” can be used for resetting the revolution counter after the axis has been rotated (no need for “rewinding” the axis).
42 Rev.N
3HAC9117-1
1 Description
1.8.1 Introduction
3HAC9117-1
Figure 24 The extreme positions of the robot arm IRB 4400/L30 (dimensions in mm).
Positions (mm) and Angles (degrees) for IRB 4400/L30:
4
5
6
2
3
0
1
Position No.
Position
(mm) X
1580
1320
919
2303
180
484
725
Position
(mm) Z
1720
2390
383
-66
-448
1804
1254
Angle
(degrees)
Axis 2
0
0
0
95
95
-70
-70
Angle
(degrees)
Axis 3
42
40
65
0
-30
65
-60
Rev.N
43
1 Description
1.8.1 Introduction
IRB 4400/L10
Type of motion
Axis 1 Rotation motion
Axis 2 Arm motion
Axis 3 Arm motion
Axis 4 Wrist motion
Axis 5 Bend motion
Axis 6 Turn motion
Range of movement
+ 165° to - 165°
+ 95° to - 70°
+ 65° to - 60°
+ 200° to - 200°
+ 120° to - 120°
+ 400° to - 400°
+183 rev.
a
to -183 rev. Max.
b a. rev. = Revolutions b. The default working range for axis 6 can be extended by changing parameter values in the software.
Option 610-1 “Independent axis” can be used for resetting the revolution counter after the axis has been rotated (no need for “rewinding” the axis).
44 Rev.N
3HAC9117-1
1 Description
1.8.1 Introduction
3HAC9117-1
Figure 25 The extreme positions of the robot arm IRB 4400/L10 (dimensions in mm).
Positions (mm) and Angles (degrees) for IRB 4400/L10:
5
6
3
4
0
1
2
Position No.
Position
(mm) X
1700
1424
970
2401
500
588
845
Position
(mm) Z
1720
2450
274
-135
-786
1864
1265
Angle
(degrees)
Axis 2
0
0
0
95
95
-70
-70
Angle
(degrees)
Axis 3
0
-30
65
-60
24
40
65
Rev.N
45
1 Description
1.8.1 Introduction
IRB 4450/S
Type of motion
Axis 1 Rotation motion
Axis 2 Arm motion
Axis 3 Arm motion
Axis 4 Wrist motion
Axis 5 Bend motion
Axis 6 Turn motion
Range of movement
+ 165° to - 165°
+ 95° to - 70°
+ 65° to - 60°
+ 200° to - 200°
+ 120° to - 120°
+ 400° to - 400°
+200 rev.
a
to -200 rev. Max.
b a. rev. = Revolutions b. The default working range for axis 6 can be extended by changing parameter values in the software.
Option 610-1 “Independent axis” can be used for resetting the revolution counter after the axis has been rotated (no need for “rewinding” the axis).
46 Rev.N
3HAC9117-1
1 Description
1.8.1 Introduction
3HAC9117-1
Figure 26 The extreme positions of the robot arm IRB 4450/S (dimensions in mm).
Positions (mm) and Angles (degrees) for IRB 4450/S:
5
6
3
4
0
1
2
Position No.
Position
(mm) X
2006
2190
1437
294
1101
1058
1195
Position
(mm) Z
556
978
-1054
-303
239
847
1208
Angle
(degrees)
Axis 2
0
0
95
95
0
-70
-70
Angle
(degrees)
Axis 3
40
65
65
40
0
-30
-60
Rev.N
47
1 Description
1.8.2 Performance according to ISO 9283
1.8.2 Performance according to ISO 9283
General
At rated load and 1,6 m/s velocity on the inclined ISO test plane with all six robot axes in motion.
The figures for AP, RP, AT and RT are mesured according to Figure 27.
48
Figure 27 Explanation of ISO values.
Pos Description
A
B
AP
RP
Pos
Programmed position E
Mean position at program execution D
Mean distance from programmed position
AT
Tolerance of posiotion B at repeated positioning
RT
Description
Programmed path
Actual path at program execution
Max deviation from E
Tolerance of the path at repeated program execution
Description Values
IRB 4400L/10 4400/30 4400/45 4400/60 4450S
Pose accuracy, AP a
(mm) 0.04
Pose repeatability, RP (mm) 0.05
Pose stabilization time, PSt (s) within 0.2 mm of the position
0.25
Path accuracy, AT (mm) 0.57
Path repeatability, RT(mm) 0.16
0.07
0.07
0.20
1.02
0.28
0.04
0.04
0.18
0.47
0.13
0.12
0.19
0.27
0.56
0.56
0.03
0.03
0.31
1.19
0.11
a. AP according to the ISO test above, is the difference between the teached position
(position manually modified in the cell) and the average position obtained during program execution.
The above values are the range of average test-results from a number of robots.
Rev.N
3HAC9117-1
1 Description
1.8.3 Velocity
1.8.3 Velocity
Resolution
Axis no.
4
5
6
1
2
3
IRB 4400/45/60/L30 and IRB 4450/S IRB 4400/L10
150°/s
120°/s
120°/s
225°/s
250°/s
330°/s
150°/s
150°/s
150°/s
370°/s
330°/s
381°/s
Supervision is required to prevent overheating in applications with intensive and frequent movements.
Approx. 0.01
o on each axis.
3HAC9117-1 Rev.N
49
1 Description
1.8.4 Stopping distance/time
1.8.4 Stopping distance/time
Stopping distance/time for emergency stop (category 0), program stop (category 1) and at mains power supply failure at max speed, max streched out and max load, categories according to EN 60204-1. All results are from tests on one moving axis.
All stop distances are valid for floor mounted robot, without any tilting.
Robot Type
IRB 4400L/10
Axis
1
2
3
Category 0 Category 1
A
45
17
13
B
0.6
0.2
0.2
A
63
28
27
B
0.8
0.3
0.3
Main power failure
A
57
25
26
B
0.7
0.3
0.3
Robot Type
IRB 4400L/30
Axis
1
2
3
Category 0 Category 1
A
68
15
21
B
0.9
0.3
0.4
A
95
22
35
B
1.2
0.4
0.6
Main power failure
A
n.a.
20
30
B
n.a.
0.3
0.4
Robot Type
IRB 4400/45
Robot Type
IRB 4400/60
Axis
1
2
3
Category 0 Category 1
A
60
15
13
B
0.9
0.3
0.2
A
73
25
22
B
0.9
0.4
0.3
Main power failure
A
46
24
22
B
0.9
0.3
0.3
Axis
1
2
3
Category 0 Category 1
A
65
16
15
B
0.9
0.3
0.3
A
84
24
25
B
1.0
0.4
0.4
Main power failure
A
76
22
23
B
0.9
0.3
0.3
A
B
Robot Type
IRB 4450/S
Axis
1
2
3
Category 0 Category 1
A
n.a.
n.a.
n.a.
B
n.a.
n.a.
n.a.
A
n.a.
n.a.
n.a.
B
n.a.
n.a.
n.a.
Main power failure
A
n.a.
n.a.
n.a.
B
n.a.
n.a.
n.a.
Description
Distance in degrees
Stop time (s)
50 Rev.N
3HAC9117-1
1 Description
1.8.5 Signals
1.8.5 Signals
Signal connections on robot arm
To connect extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling, one FCI UT07 14 12SH44N connector and one FCI UT07 18 23SH44N connector on the rear part of the upper arm.
Hose for compressed air is also integrated into the manipulator. There is an inlet
(R1/4”) at the base and an outlet (R1/4”) on the rear part of the upper arm.
Signals
Power
Air
Number
23
10
1
Value
50 V, 250 mA
250 V, 2 A
Max. 8 bar, inner hose diameter 8 mm
3HAC9117-1 Rev.N
51
1 Description
1.8.5 Signals
52 Rev.N
3HAC9117-1
2 Specification of Variants and Options
2.1.1 General
2 Specification of Variants and Options
2.1 Introduction
2.1.1 General
The different variants and options for the IRB 4400 are described below.
The same numbers are used here as in the Specification form. For controller, see
Product specification - Controller IRC5 with FlexPendant and for software options, see Product specification - Controller software IRC5/RobotWare.
2.1.2 Manipulator
Variants
Option
435-37
435-38
435-42
435-41
435-62
IRB Type
IRB 4000/45
IRB 4400/60
IRB 4400/L30
IRB 4400/L10
IRB 4450S
Handling capacity (kg) / Reach (m)
45/1.96
60/1.96
30/2.43
10/2.55
30/2.40
Manipulator color
Option Description
209-1 Protection Standard and Foundry have color ABB Orange and protection
Clean Room has color white
209-4--192 The manipulator is painted with the chosen RAL-color.
3HAC9117-1 Rev.N
53
2 Specification of Variants and Options
2.1.2 Manipulator
Protection
Option
287-4
287-3
287-1
287-6
Description
Standard
Foundry
Robot adapted for foundry or other harsh environments.
The robot has the FoundryPlus protection which means that the whole manipulator is IP67 classified and steam washable. An excellent corrosion protection is obtained by a special coating. The connectors are designed for severe environments, and bearings, gears and other sensitive parts are highly protected.
The robot is labeled with “Foundry Plus”.
Clean Room
Robot with clean room class 100 according to US Federal Standard 209 and with the same protection as in option 287-4.
Standard color is white. The robot is labeled with “Clean Room”.
Foundry Prime a
Robots adapted for water jet cleaning of casts and machined parts, and similar very harsh environments. The manipulator can withstand surrounding solvent based detergent (max. pH 9.0 and must contain rust inhibitor). The detergent must be approved by ABB. In addition, the manipulator can withstand indirect spray from jet pressure (max. 600 bar) and 100% humidity. The manipulator can work in an environment with a cleaning bath temperature < 60
0
C, typically used in a water jet cleaning application with moderate speed.
The robot is labeled “Foundry Prime”.
The following options are NOT selectable together with option 287-6:
• 209-2 ABB White standard
• 209 RAL code
• 218-6 At upper arm axis 4
• 426-1 Position switches kit
• 213-1 Safety lamp
• 25-2/-3/-4 Position switches axis 1
• 271-1/-2 Position switch Connection to
• 34-1 Axis 3 work range limit
• 429-1 Underwriters Laboratories
• 438-5 Standard + 24 months
• 438-7 Standard + 30 months a. Only available for IRB 4400/60
54 Rev.N
3HAC9117-1
2 Specification of Variants and Options
2.1.2 Manipulator
Application interface
Air supply and signals for extra equipment to upper arm:
Option
218-8
Description
Integrated hose and cables for connection of extra equipment on the manipulator to the rear end of the upper arm.
Figure 28 Integrated hose and cables.
Option
218-6
Description
Hose and cables for connection of extra equipment are continuing to the wrist on the outside of the upper arm.
Not available for options 435-41, 435-42, 435-43, 287-3 and 287-5.
Figure 29 Hose and cables.
3HAC9117-1 Rev.N
55
2 Specification of Variants and Options
2.1.2 Manipulator
Application interface Connection to
Option
16-1 a
Description
Cabinet
The signals are connected to 12-pole screw terminals,
Phoenix MSTB 2.5/12-ST-5.08, to the the controller.
a. Note! In a M2004 MultiMove application additional robots have no Control Module. The screw terminals with internal cabling are then delivered separately to be mounted in the main robot Control Module or in another encapsulation, for example a PLC cabinet.
Figure 30 Connection to cabinet.
Pos
A
B
Description
If 218-6
If 16-1
Application equipment cable lengths
If connection to Cabinet:
Option
94-1
94-2
94-3
94-4
Lengths
7 m
15 m
22 m
30 m
Safety lamp
Option
213-1
Description
Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
56 Rev.N
3HAC9117-1
2 Specification of Variants and Options
2.1.2 Manipulator
Electronic Position Switches (EPS)
The mechanical position switches indicating the position of the three main axes are replaced with electronic position switches for up to 7 axes, for increased flexibility and robustness.
For more detailed information, see Product specification - Controller IRC5 with
FlexPendant and Application Manual Electronic Position Switches, art. No.
3HAC0277709-001.
Connector kit
Detached connectors, suitable to the connectors for the application interface and position switches.
The kit consists of connectors, pins and sockets.
Option
431-1
239-1
426-1
Description
For the connectors on the upper arm.
For the connectors on the foot if connection to manipulator, option 16-2.
For connection to position switches and connection to manipulator, option 271-2 and position switch(es).
3HAC9117-1 Rev.N
57
2 Specification of Variants and Options
2.1.2 Manipulator
Working range limit
Figure 31 Mounting area of the stops, axis 1
Option Description
28-1 Axis 1 Two extra stops for restricting the working range.The stops can be mounted
within the area from 65° to 125°. See Figure 31.
IRB 4400/45 IRB 4400/60 IRB 4400/L30 IRB 4400/L10
58
Figure 32 Mounting positions of the stops, axis 2.
Option Description
32-1 Axis 2
Stop lugs for restricting the working range. Figure 33 illustrates the mounting
positions of the stops.
Rev.N
3HAC9117-1
2 Specification of Variants and Options
2.1.2 Manipulator
IRB 4450/S
Warranty
Figure 33 Mounting positions of the stops, axis 2
Option Description
34-1Axis 3 Equipment for electrically restricting the working range in increments of 5°.
Option
438-1
438-2
438-4
438-5
438-6
438-8
Type
Standard Warranty
Standard + 12 months
Standard + 18 months
Standard + 24 months
Standard + 6 months
Stock Warranty
Description
Standard warranty is 18 months (1 1/2 years)
18 + 12 months (2 1/2 years)
18 + 18 months (3 years)
18 + 24 months (3 1/2 years)
18 + 6 months (2 years)
Maximum 6 months postponed warranty starting from shipment date ABB Robotics Production unit (PRU) + Option 438-1. Warranty commences automatically after 6 months or from activation date of standard warranty. (See ABB Robotics
BA Warranty Rules).
3HAC9117-1 Rev.N
59
2 Specification of Variants and Options
2.1.3 Floor cables
2.1.3 Floor cables
Manipulator cable length
Option
210-2
210-3
210-4
210-5
Lengths
7 m
15 m
22 m
30 m
Connection of parallel communication
Option
94-1
94-2
94-3
94-4
Lengths
7 m
15 m
22 m
30 m
2.1.4 Documentation
DVD User Documentation
Option Type
808-1
Description
Documentation on DVD See Product specification Robot User Documentation
60 Rev.N
3HAC9117-1
3 Accessories
3 Accessories
Basic software and software options for robot and PC
For more information, see Product specification - Controller IRC5 with Flex-
Pendant and Product specification - Controller software IRC5/RobotWare.
Robot Peripherals
• Track Motion
• Motor Units
3HAC9117-1 Rev.N
61
3 Accessories
62 Rev.N
3HAC9117-1
Index
A
accessories
accuracy
air supply
,
C
connector kit
,
cooling device
,
E
emergency stop
enabling device
equipment mounting
permitted extra load
,
extra equipment connections
,
F
fire safety
forklift
H
hold-to-run control
humidity
I
installation
,
L
load
,
load diagrams
M
maintenance
,
manipulator colours
mechanical interface
motion
mounting extra equipment
,
robot
,
mounting flange
,
N
noise level
O
operating requirements
,
options
overspeed protection
P
path
,
payload
performance
,
pose
protection standards
3HAC9117-1 Rev.N
R
range of movement working space
reduced speed
,
repeatability
Robot Peripherals
robot versions
,
S
safeguarded space stop
,
delayed
safety
safety lamp
service
,
service position indicator
signal connections
,
space requirements
,
stabilization time
standards
structure
T
temperature
troubleshooting
,
V
Variants
variants
,
W
working space restricting
63
Index
64 Rev.N
3HAC9117-1
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592
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