ABB IRB 4600 Foundry Prime Product Manual

ROBOTICS

Product manual

IRB 4600 Foundry Prime

Trace back information:

Workspace R18-2 version a18

Checked in 2018-11-20

Skribenta version 5.3.012

Product manual

IRB 4600 Foundry Prime - 60/2.05

IRC5

Document ID: 3HAC040585-001

Revision: M

© Copyright 2013-2018 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, 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.

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.



ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents


Overview of this manual ...................................................................................................................

Product documentation ....................................................................................................................

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

Important information about robots with protection type Foundry Prime ......................................

9

13

15

16

1 Safety

1.1

General safety information ..................................................................................

1.1.1

Limitation of liability .................................................................................

1.1.2

Protective stop and emergency stop ...........................................................

1.2

Safety actions ...................................................................................................

1.2.1

Fire extinguishing ....................................................................................

1.2.2

Emergency release of the robot axes ..........................................................

1.2.3

Make sure that the main power has been switched off ....................................

1.3

Safety risks ......................................................................................................

1.3.1

Safety risks during installation and service work on robots ..............................

1.3.2

Moving robots are potentially lethal ............................................................

1.3.3

First test run may cause injury or damage ....................................................

1.3.4

Work inside the working range of the robot ..................................................

1.3.5

Enabling device and hold-to-run functionality ...............................................

1.3.6

Risks associated with live electric parts .......................................................

1.3.7

The unit is sensitive to ESD .......................................................................

1.3.8

Hot parts may cause burns .......................................................................

1.3.9

Safety risks related to pneumatic/hydraulic systems ......................................

1.3.10 Safety risks with pressure relief valve .........................................................

1.3.11 Brake testing ..........................................................................................

1.3.12 Safety risks during handling of batteries ......................................................

1.3.13 Safety risks during work with gearbox lubricants (oil or grease) .......................

1.4

Safety signals and symbols .................................................................................

1.4.1

Safety signals in the manual ......................................................................

1.4.2

Safety symbols on product labels ...............................................................

17

28

29

31

32

23

25

26

27

20

21

22

23

17

17

19

20

37

39

39

41

33

34

35

36

2 Installation and commissioning

2.1

Introduction ......................................................................................................

2.2

Installation and operational requirements for Foundry Prime robots ............................

2.3

Unpacking .......................................................................................................

2.3.1

Pre-installation procedure .........................................................................

2.3.2

Surface inspection before start-up - Foundry Prime .......................................

2.3.3

Working range and type of motion ..............................................................

2.3.4

Risk of tipping/stability .............................................................................

2.4

On-site installation ............................................................................................

2.4.1

Lifting robot with roundslings ....................................................................

2.4.2

Lifting and turning a suspended mounted robot ............................................

2.4.3

Setting the system parameters for a suspended or tilted robot .........................

2.4.4

Manually releasing the brakes ...................................................................

2.4.5

Orienting and securing the robot ................................................................

2.4.6

Fitting equipment on robot ........................................................................

2.4.7

Surface inspection before start-up - Foundry Prime .......................................

2.4.8

Loads fitted to the robot, stopping time and braking distances .........................

2.4.9

Installation of signal lamp (option) ..............................................................

2.5

Restricting the working range ..............................................................................

2.5.1

Axes with restricted working range .............................................................

2.5.2

Mechanically restricting the working range of axis 1 ......................................

2.6

Installing options ...............................................................................................

2.6.1

Installing an expansion container ...............................................................

2.7

Robot in hot environments ..................................................................................

2.7.1

Start of robot in hot environments ..............................................................

47

69

72

76

82

61

61

64

65

47

48

52

52

56

57

60

86

89

89

92

92

83

84

85

85

Product manual - IRB 4600 Foundry Prime

3HAC040585-001 Revision: M


5


2.8

Robot in cold environments .................................................................................

2.8.1

Start of robot in cold environments ............................................................

2.9

Electrical connections ........................................................................................

2.9.1

Robot cabling and connection points ..........................................................

2.9.2

Customer connection on robot ...................................................................

2.9.3

Customer connections on upper arm ..........................................................

2.10 Additional installation (Foundry Prime) ..................................................................

2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application ......................

2.10.2 Commissioning (Foundry Prime) ................................................................

93

93

94

94

96

99

101

101

105

3 Maintenance 107

3.1

Introduction ......................................................................................................

3.2

Introduction for Foundry Prime robots ...................................................................

3.3

Maintenance schedule .......................................................................................

3.3.1

Specification of maintenance intervals ........................................................

3.3.2

Maintenance schedule .............................................................................

3.3.3

Expected component life .........................................................................

3.4

Inspection activities ...........................................................................................

3.4.1

Inspecting oil level, axis 1 gearbox .............................................................

3.4.2

Inspecting the oil level, axis 2 gearbox ........................................................

3.4.3


3.4.4


3.4.5

Inspecting oil level, gearbox axes 5 - 6 ........................................................

3.4.6

Inspecting the cable harness .....................................................................

3.4.7

Inspecting information labels .....................................................................

3.4.8

Inspecting the mechanical stop pin, axis 1 ...................................................

3.4.9

Inspecting additional mechanical stops .......................................................

3.4.10 Inspecting dampers .................................................................................

3.4.11 Inspecting the leak proof o-ring and pressure relief valves ..............................

3.4.12 Inspecting Signal lamp (option) ..................................................................

3.4.13 Inspection of air hoses (Foundry Prime) ......................................................

3.4.14 Inspection of surface treatment (Foundry Prime) ...........................................

3.5

Replacement activities .......................................................................................

3.5.1

Type of lubrication in gearboxes ................................................................

3.5.2

Changing the oil, axis 1 gearbox on floor mounted robots ...............................

3.5.3

Changing the oil, axis-1 gearbox on suspended robots ...................................

3.5.4

Changing the oil, axis-2 gearbox ................................................................

3.5.5


3.5.6


3.5.7

Changing oil, axes-5 and -6 gearboxes ........................................................

3.5.8

Replacing SMB battery .............................................................................

3.6

Analysis activities ..............................................................................................

3.6.1

Analyzing the water content in gearbox oil ...................................................

3.7

Cleaning activities .............................................................................................

3.7.1

Cleaning the IRB 4600 Foundry Prime .........................................................

153

160

167

171

177

181

185

190

139

141

143

146

148

150

151

151

190

191

191

113

119

122

125

127

131

133

135

107

108

109

109

110

112

113

4 Repair 195

4.1

Introduction ......................................................................................................

4.2

General procedures ...........................................................................................

4.2.1

Performing a leak-down test ......................................................................

4.2.2

Mounting instructions for bearings .............................................................

4.2.3

Mounting instructions for seals ..................................................................

4.2.4

Cut the paint or surface on the robot before replacing parts ............................

4.2.5

The brake release buttons may be jammed after service work .........................

4.3

Complete robot .................................................................................................

4.3.1

Removing the complete cable harness ........................................................

4.3.2

Refitting the complete cable harness ..........................................................

4.3.3

Replacement of air nipples and hoses (Foundry Prime) ..................................

4.3.4

Replacing SMB unit .................................................................................

195

196

196

197

199

201

203

204

204

217

233

245

6 Product manual - IRB 4600 Foundry Prime




4.3.5

Replacing the brake release board .............................................................

4.3.6

Replacing the base ..................................................................................

4.4

Upper arm .......................................................................................................

4.4.1

Replacing the complete upper arm .............................................................

4.4.2

Replacing complete tubular shaft unit .........................................................

4.4.3

Replacing wrist unit .................................................................................

4.4.4

Measuring the play, axis 5 .........................................................................

4.4.5

Measuring the play, axis 6 .........................................................................

4.5

Lower arm .......................................................................................................

4.5.1

Replacing the lower arm ...........................................................................

4.6

Frame and base ................................................................................................

4.6.1

Replacing stop pin axis 1 ..........................................................................

4.7

Motors ............................................................................................................

4.7.1

Removing motors ....................................................................................

4.7.2

Refitting motors ......................................................................................

4.7.3

Adjusting the play of axis 4, 5 and 6 motors .................................................

4.8

Gearboxes .......................................................................................................

4.8.1

Replacing gearbox axis 1 ..........................................................................

4.8.2


4.8.3


292

295

295

301

301

305

305

314

252

257

267

267

277

284

290

325

326

326

336

345

5 Calibration 353

5.1

Introduction to calibration ...................................................................................

5.1.1

Introduction and calibration terminology ......................................................

5.1.2

Calibration methods .................................................................................

5.1.3

When to calibrate ...................................................................................

5.2

Synchronization marks and axis movement directions .............................................

5.2.1

Synchronization marks and synchronization position for axes .........................

5.2.2

Calibration movement directions for all axes ................................................

5.3

Updating revolution counters ...............................................................................

5.4

Calibrating with Axis Calibration method ...............................................................

5.4.1

Description of Axis Calibration ..................................................................

5.4.2

Calibration tools for Axis Calibration ...........................................................

5.4.3

Installation locations for the calibration tools ...............................................

5.4.4

Axis Calibration - Running the calibration procedure ......................................

5.5

Calibrating with Calibration Pendulum method ........................................................

5.6

Verifying the calibration ......................................................................................

5.7

Checking the synchronization position ..................................................................

364

364

367

369

371

378

379

380

353

353

354

356

357

357

359

360

6 Decommissioning 381

6.1

Introduction ......................................................................................................

6.2

Environmental information ..................................................................................

6.3

Scrapping of robot .............................................................................................

381

382

384

7 Reference information 385

7.1

Introduction ......................................................................................................

7.2

Applicable standards .........................................................................................

7.3

Unit conversion .................................................................................................

7.4

Screw joints ....................................................................................................

7.5

Weight specifications .........................................................................................

7.6

Standard tools ..................................................................................................

7.7

Special tools ....................................................................................................

7.8

Lifting accessories and lifting instructions ..............................................................

385

386

388

389

392

393

394

397

8 Spare part lists 399

8.1

Spare part lists and illustrations ...........................................................................

399




7


9 Circuit diagram 401

9.1

Circuit diagrams ................................................................................................

401

Index 403




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 Foundry Prime .

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

Maintenance/repair/installation personnel working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.

Product manual scope

The manual covers covers all variants and designs of the IRB 4600 Foundry Prime.

Some variants and designs may have been removed from the business offer and are no longer available for purchase.

Organization of chapters

The manual is organized in the following chapters:

Chapter Contents

Safety 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.

Installation and commissioning

Required information about lifting and installation of the robot.

Maintenance Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used to plan periodical maintenance.

Continues on next page





Continued

Chapter

Repair

Calibration

Decommissioning

Reference information

Spare part / part list

Exploded views

Circuit diagram

Contents

Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts.

Calibration procedures and general information about calibration.

Environmental information about the robot and its components.

Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards etc.

Complete spare part list and complete list of robot components, shown in exploded views.

Detailed illustrations of the robot with reference numbers to the part list.

Reference to the circuit diagram for the robot.

References

Reference

Product manual - IRB 4600

Product manual, spare parts - IRB 4600

Product specification - IRB 4600

Circuit diagram - IRB 4600

Operating manual - General safety information i

Document ID

3HAC033453-001

3HAC049108-001

3HAC032885-001

3HAC029038-003

3HAC031045-001

Product manual - IRC5

IRC5 with main computer DSQC 639.

Product manual - IRC5

IRC5 with main computer DSQC1000.

Operating manual - Emergency safety information

Operating manual - IRC5 with FlexPendant

Operating manual - Troubleshooting IRC5

Operating manual - Calibration Pendulum

Operating manual - Service Information System

Technical reference manual - Lubrication in gearboxes

Technical reference manual - System parameters

3HAC021313-001

3HAC047136-001

3HAC027098-001

3HAC050941-001

3HAC020738-001

3HAC16578-1

3HAC050944-001

3HAC042927-001

3HAC050948-001

Application manual - Additional axes and stand alone controller 3HAC051016-001

Application manual - Electronic Position Switches 3HAC050996-001

Application manual - CalibWare Field 5.0

3HAC030421-001 i

List of approved cleaners and detergents for Foundry Prime robots

Contact ABB local sales organization

This manual contains all safety instructions from the product manuals for the manipulators and the controllers.

Revisions

-

Revision


10

Description

First edition





Continued

Revision

A

B

C

D

E

F

G

H

Description

The following updates have been made in this revision:

• A new SMB unit and battery is introduced, with longer battery lifetime.

• Updated the list of approved detergents, see

Approved cleaners and detergents on page 193

.


• Several more spare part numbers are corrected throughout the spare part chapter.

• The list of approved cleaners and detergents is updated more frequently than the manual is updated, therefore the information is removed from the manual and instead referenced. See

Approved cleaners and detergents on page 193 .


• Added information about risks when scrapping a decommissioned robot, see

Scrapping of robot on page 384

.


• Illustration changes in

Dimension, mounting surface and guide bushing on page 73

.

• Term "Guide sleeves" changed to "Guide bushings", see

Dimension, mounting surface and guide bushing on page 73

.

• A new WARNING ! is added in the section about motor replacement, informing not to mix different motor types.

• Minor corrections.


• Note added in Fitting equipment on robot.

• Foundry Prime: Seal armhouse cover with Sikaflex (several updates)


• Turning disc fixture is removed from special tools for Levelmeter calibration.

• New illustrations for foundry prime air connections in manipulator base, maintenance and repair chapter.

Published in release R16.2. The following updates are made in this revision:

• Corrections due to updates in terminology.

• New dimensional drawing of the turning disk added to

Fitting equipment on wrist and mounting flange on page 80

.

• New standard calibration method is introduced (Axis Calibration). See

Calibration on page 353

.

• Information about grounding point added. See

Robot cabling and connection points on page 94 .

• The spare part lists are removed from this manual. Valid spare part lists are published in Product manual, spare parts - IRB 4600 .

• The maintenance schedule is revised, activities not valid for IRB 4600 were incorrectly added to the schedule previously. Faulty activities are removed.


• Drying time for Mercasol added.

• Changed the tightening torque of the oil plug located on axis-1 gearbox.

• Added information regarding tightening of protective calibration plugs after calibration. Risk of damage on sealing washer if tightened too hard.





11


Continued

Revision

J

K

L

M

Description


• Information about coupled axes in

Updating revolution counters on page 360

.

• Caution about removing metal residues added in sections about SMB boards.

• Information about minimum resonance frequency added.

• Bending radius for static floor cables added.

• Updated list of applicable standards.

• Article number for the Calibration tool box, Axis Calibration is changed.

• Added text regarding overhaul in section specification of maintenance intervals.

• Updated the section

Start of robot in cold environments on page 93 .

• Updated information regarding replacement of brake release board.

• Updated information about leak proof o-ring/pressure relief valve.

• Definition of reference calibration clarified.


• Information added about fatigue to Axis Calibration tool, see

Calibration tools for Axis Calibration on page 367

.

• Added sections in

General procedures on page 196

.

• Updated figure of axis-6 synchronization mark.

• Updated

Activities and intervals, Foundry Prime on page 110

and Oil in axis-5 & -6 gearbox.

• New spare parts numbers for brake release boards.

• Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previously created reference calibration values.

• Information about myABB Business Portal added.

• Added Nickel in Environmental information.


• Updates related to mechanical stop pin.

• Changed the method for replacing the axis-1 gearbox and the base.


• Updated references.




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.

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

.

Product manuals

Manipulators, controllers, DressPack/SpotPack, 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.

• 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.

• Examples of how to use the application.





13


Continued

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 references to figures, tools, material, and so on. The references are read as described below.

References to figures

The procedures often include references to components or attachment points located on the manipulator/controller. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown.

The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in a procedure.

8.

Action

Remove the rear attachment screws, gearbox.

Note/Illustration

Shown in the figure Location of gearbox on page xx .

References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, that is article number and dimensions.

The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list.

The table below shows an example of a reference to a list of required equipment from a step in a procedure.

3.

Action

Fit a new sealing, axis 2 to the gearbox.


Art. no. is specified in Required equipment on page xx.

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 robot 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 robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual.




15

Important information about robots with protection type Foundry Prime

Important information about robots with protection type

Foundry Prime

Introduction

Foundry Prime robots are specially designed to work in harsh environments. Misuse of the robots or poor installation, cleaning, maintenance and repair can be harmful for the functioning of the robot.

Warranty claims

Warranty claims for defect products due to misuse or failure to fulfil operational and maintenance requirements will not be approved.

Pressurized components

Motors, balancing device and the serial measurement board cavity shall be pressurized on Foundry Prime robots during operation and shut down. The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment.

For more information, see

Pressurized components on page 48

.

Cleaning

Special procedures are needed when cleaning the Foundry Prime robot. See section

Cleaning the IRB 4600 Foundry Prime on page 191 .




1 Safety

1.1.1 Limitation of liability

1 Safety

1.1 General 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 complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.

In particular, liability cannot be accepted if injury/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.

• Non-authorized design modifications made in or around the robot.

• Repairs carried out by in-experienced or non-qualified personnel.

• Foreign objects.

• Force majeure.

Nation/region specific regulations

To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.

To be observed by the supplier of the complete system

The integrator is responsible 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 and machines:

• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

• The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.





17

1 Safety

1.1.1 Limitation of liability

Continued

The integrator of the final application is required to perform an assessment of the hazards and risks (HRA).

Note

The integrator is responsible for the safety of the final application.

Safe access

The robot system shall be designed to allow safe access to all areas where intervention is necessary during operation, adjustment, and maintenance.

Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations.

Safety zones, which must be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

Turntables or the like should be used to keep the operator out of the robot's working space.

A safety fence is recommended to ensure safeguarded space. Sufficient space must be provided around the manipulator to protect those working with or on it from hazards such as crushing.

The fence or enclosure must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see the section

Robot motion in the Product specification ).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.

Safe handling

Users shall not be exposed to hazards, including slipping, tripping, and falling hazards.

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. If any of the buttons do not stop all the robot workcell motion, each emergency stop button must be marked, if more than one is provided, to indicate its designated safety function.

Grippers/end effectors must be designed so that they do not drop work pieces/tools in the event of a power failure or a disturbance to the controller.

Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.




1 Safety

1.1.2 Protective stop and emergency stop

1.1.2 Protective stop and emergency stop

Overview

The protective stops and emergency stops are described in the product manual for the controller.




19

1 Safety

1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the manipulator or controller.




1 Safety

1.2.2 Emergency release of the robot axes

1.2.2 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 69 .

The robot may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar equipment.

Increased injury

Before releasing the brakes, make sure that the weight of the robot does not increase the pressure on the trapped person, further increasing any injury.

DANGER

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways.

Make sure no personnel is near or beneath the robot.




21

1 Safety

1.2.3 Make sure that the main power has been switched off

1.2.3 Make sure that the main power has been switched off

Description

Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these personal injuries, switch off the main power on the controller before proceeding work.

Note

Switch off all main power switches in a MultiMove system.




1 Safety

1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

Requirements on personnel

Only persons who know the robot and are trained in the operation and handling of the robot are allowed to maintain the robot. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, repair, or use the robot.

• Those in charge of operations must make sure that safety instructions are available for the installation in question.

• Those who install or service/maintain the robot must have the appropriate training for the equipment in question and in any safety matters associated with it.

• Personnel should be trained on responding to emergency or abnormal situations.

General risks during installation and service

The instructions in the product manual must always be followed.

Never turn the power on to the robot before it is properly fixed and bolted to its foundation/support.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to remove the power cable to the controller.

If the robot is installed at a height, hanging, or other than standing directly on the floor, there may be additional risks than those for a robot standing directly on the floor.

Energy stored in the robot for the purpose of counterbalancing certain axes may be released if the robot, or parts thereof, are dismantled.

Never use the robot as a ladder, which means, do not climb on the controller, motors, or other parts during service work. There is a risk of slipping because of the high temperature of the motors and oil spills that can occur on the robot. There is also a risk of the robot being damaged.

To avoid damaging the product, make sure that there are no loose screws, turnings, or other parts inside the product after work has been performed.

Safety risks during operational disturbances

Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.





1 Safety

1.3.1 Safety risks during installation and service work on robots

Continued

If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been tested and approved by ABB. The installation and/or use of such products could negatively affect the structural properties of the robot and as a result of that affect the active or passive safety operation. ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. An external safety function can interact with other machines and peripheral equipment via this interface. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment for the installation.

Allergenic material

See

Environmental information on page 382

for specification of allergenic materials in the product, if any.




1 Safety

1.3.2 Moving robots are potentially lethal

1.3.2 Moving robots are potentially lethal

Description

Any moving robot is a potentially lethal machine.

When running, the robot may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the robot.

Safe handling

1

2

3

Action Note

Before attempting to run the robot, make sure all emergency stop equipment is correctly installed and connected.

Emergency stop equipment such as gates, tread mats, light curtains, etc.

Usually the hold-to-run function is active only in manual full speed mode. To increase safety it is also possible to activate hold-to-run for manual reduced speed with a system parameter.

The hold-to-run function is used in manual mode, not in automatic mode.

How to use the hold-to-run function is described in section How to use the hold-torun function in the Operating manual - IRC5 with FlexPendant .

Make sure no personnel are present within the working range of the robot before pressing the start button.




25

1 Safety

1.3.3 First test run may cause injury or damage

1.3.3 First test run may cause injury or damage

Description

After installation and performing service activities, there are several safety risks to take into consideration before the first test run.

Safe handling

Use this procedure when performing the first test run after installation, maintenance, or repair.

DANGER

Running the robot without fulfilling the following aspects, may involve a risk of injury and cause severe damage to the robot.

1

2

3

4

5

6

7

Action

Remove all tools and foreign objects from the robot and its working area.

Verify that the robot is properly secured to its position by all screws, before it is powered up.

Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed.

Verify that the fixture and work piece are well secured, if applicable.

Install all safety equipment properly.

Make sure all personnel are standing at a safe distance from the robot, and is out of its reach behind safety fences, or similar.

If maintenance or repair has been done, pay special attention to the function of the part that was serviced.

Collision risks

CAUTION

When programming the movements of the robot, always identify potential collision risks before the first test run.

Mechanical stops will not always stop the movements of the robot completely.




1 Safety

1.3.4 Work inside the working range of the robot

1.3.4 Work inside the working range of the robot

WARNING

If work must be carried out within the work area of the robot, then the following points must be observed:

• The operating mode selector on the controller must be in the manual mode position to render the three-position enabling device operational and to block operation from a computer link or remote control panel.

• The maximum speed of the robot is limited to 250 mm/s when the operating mode selector is in the position Manual mode with reduced speed . This should be the normal position when entering the working space.

The position Manual mode with full speed (100%) may only be used by trained personnel who are aware of the risks that this entails.

Manual mode with full speed (100%) is not available in USA or Canada.

• Pay attention to the rotating axes of the robot. Keep away from axes to not get entangled with hair or clothing. Also, be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell.

• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped or crushed by the robot.

• To prevent anyone else from taking control of the robot, always put a safety lock on the cell door and bring the three-position enabling device with you when entering the working space.

WARNING

NEVER , under any circumstances, stay beneath any of the robot's axes! There is always a risk that the robot will move unexpectedly when robot axes are moved using the three-position enabling device or during other work inside the working range of the robot.




27

1 Safety

1.3.5 Enabling device and hold-to-run functionality

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely.

The three-position enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, operating the robot is impossible.

Note

The three-position enabling device is a push-button located on the teach pendant which, when pressed halfway in, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state.

To ensure safe use of the teach pendant, the following must be implemented:

• The enabling device must never be rendered inoperational in any way.

• During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.

• Anyone entering the working space of the robot must always hold the teach pendant. This is to prevent anyone else from taking control of the robot without his/her knowledge.

Hold-to-run function

The hold-to-run function allows movement when a button connected to the function is actuated manually and immediately stops any movement when released. The hold-to-run function can only be used in manual mode.

How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant .




1 Safety

1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified electrician in accordance with electrical regulations.

Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the main switch to

OFF) when repairing faults, disconnecting electric leads, and disconnecting or connecting units.

The main supply to the robot must be connected in such a way that it can be turned off from outside the working space of the robot.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

The necessary protection for the electrical equipment and robot during installation, commissioning, and maintenance is guaranteed if the valid regulations are followed.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:

• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

• Units such as I/O modules, can be supplied with power from an external source.

• The main supply/main switch

• The transformers

• The power unit

• The control power supply (230 VAC)

• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)

• The drive unit (400/700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

• The power supply unit for additional tools, or special power supply units for the machining process.

• The external voltage connected to the controller remains live even when the robot is disconnected from the mains.

• Additional connections.

Voltage related risks, manipulator

A danger of low voltage is associated with the manipulator in:

• The power supply for the motors (up to 800 VDC).

• The user connections for tools or other parts of the installation (max. 230

VAC).





1 Safety

1.3.6 Risks associated with live electric parts

Continued

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.




1 Safety

1.3.7 The unit is sensitive to ESD

1.3.7 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

1

2

3

Action Note

Use a wrist strap. The wrist strap button is located inside the controller.

Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

• Product manual - IRC5

• Product manual - IRC5 Panel Mounted

Controller

Use an ESD protective floor mat.

Use a dissipative table mat.

The mat must be grounded through a current-limiting resistor.

The mat should provide a controlled discharge of static voltages and must be grounded.




31

1 Safety

1.3.8 Hot parts may cause burns

1.3.8 Hot parts may cause burns

Description

During normal operation, many parts become hot. Touching these may cause burns.

There is also a risk of fire if flammable materials are put on hot surfaces.

Safe handling

Always use your hand, at some distance, to feel if heat is radiating from the potentially hot component before actually touching it.

Wait until the potentially hot component has cooled if it is to be removed or handled in any other way.

Do not put anything on hot metal surfaces, e.g. paper or plastic.




1 Safety

1.3.9 Safety risks related to pneumatic/hydraulic systems

1.3.9 Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from the power supply must be provided with clearly visible drain facilities and a warning sign that indicates the need for pressure relief before adjustments or performing any maintenance on the robot system.

Residual energy

Residual energy can be present in these systems. After shutdown, particular care must be taken.

The pressure must be released in the complete pneumatic or hydraulic systems before starting to repair them.

Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics.

All pipes, hoses, and connections have to be inspected regularly for leaks and damage. Damage must be repaired immediately.

Splashed oil may cause injury or fire.

Safe design

Gravity may cause any parts or objects held by these systems to drop.

Dump valves should be used in case of emergency.

Shot bolts should be used to prevent tools, etc., from falling due to gravity.




33

1 Safety

1.3.10 Safety risks with pressure relief valve

1.3.10 Safety risks with pressure relief valve

Introduction

The pressure relief valve must be kept clean and open, for it to be able to function properly.

Safety risks

The pressure relief valve is a vital part preventing too much air pressure being built up inside the robot. If too much air pressure has been built up, there is a risk of personal injury and mechanical damage.




1 Safety

1.3.11 Brake testing

1.3.11 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 robot axis to a position where the combined weight of the robot arm 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 robot does not change position as the motors are switched off, then the brake function is adequate.




35

1 Safety

1.3.12 Safety risks during handling of batteries

1.3.12 Safety risks during handling of batteries

Description

Under normal conditions of use, the electrode materials and liquid electrolyte in the batteries are not exposed to the outside, provided the battery integrity is maintained and seals remain intact.

There is a risk of exposure only in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery container. Electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Safe handling

Use safety glasses when handling the batteries.

In the event of leakage, wear rubber gloves and chemical apron.

In the event of fire, use self-contained breathing apparatus.

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

Pre-installation procedure on page 52

.




1 Safety

1.3.13 Safety risks during work with gearbox lubricants (oil or grease)

1.3.13 Safety risks during work with gearbox lubricants (oil or grease)

Description

When handling gearbox lubricants, there is a risk of both personal injury and product damage occurring. The following safety information must be regarded before performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety information of the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must be provided. Gloves and goggles are recommended.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Safe handling

Warning Description Elimination/Action

Changing and draining gearbox oil or grease may require handling hot lubricant heated up to

90 °C.

Make sure that protective gear like goggles and gloves are always worn during this activity.

Hot oil or grease

When working with gearbox lubricant there is a risk of an allergic reaction.

Make sure that protective gear like goggles and gloves are always worn.

Allergic reaction

Possible pressure build-up in gearbox

When opening the oil or grease plug, there may be pressure present in the gearbox, causing lubricant to spray from the opening.

Open the plug carefully and keep away from the opening. Do not overfill the gearbox when filling.





37

1 Safety

1.3.13 Safety risks during work with gearbox lubricants (oil or grease)

Continued

Warning

Do not overfill

Description Elimination/Action

Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may:

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the robot from moving freely.

Make sure not to overfill the gearbox when filling it with oil or grease.

After filling, verify that the level is correct.

Do not mix types of oil

Mixing types of oil may cause severe damage to the gearbox.

When filling gearbox oil, do not mix different types of oil unless specified in the instructions. Always use the type of oil specified by the manufacturer.

Warm oil drains quicker than cold oil.

When changing gearbox oil, first run the robot for a time to heat up the oil.

Heat up the oil

Specified amount depends on drained volume

The specified amount of oil or grease is based on the total volume of the gearbox. When changing the lubricant, the amount refilled may differ from the specified amount, depending on how much has previously been drained from the gearbox.

After filling, verify that the level is correct.

Contaminated oil in gear boxes

When draining the oil make sure that as much oil as possible is drained from the gearbox. The reason for this is to drain as much oil sludge and metal chips as possible from the gearbox.

The magnetic oil plugs will take care of any remaining metal chips.




1 Safety

1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal consists of:

• A caption specifying the danger level (DANGER, WARNING, or CAUTION) and the type of danger.

• A brief description of what will happen if the the danger is not eliminated.

• Instruction about how to eliminate danger to simplify doing the work.

Danger levels

The table below defines the captions specifying the danger levels used throughout this manual.

Symbol Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Significance

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply 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, and so on.

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 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.

Warns for electrical hazards which could result in severe personal injury or death.

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, impact, 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.

ELECTROSTATIC

DISCHARGE (ESD)

Warns for electrostatic hazards which could result in severe damage to the product.





39

1 Safety

1.4.1 Safety signals in the manual

Continued

Symbol Designation

NOTE

Significance

Describes important facts and conditions.

TIP Describes where to find additional information or how to do an operation in an easier way.




1 Safety

1.4.2 Safety symbols on product labels

1.4.2 Safety symbols on product labels

Introduction to labels

This section describes safety symbols used on labels (stickers) on the product.

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 safety and health symbols on the labels on the product must be observed.

Additional safety information given by the system builder or integrator must also be observed.

Types of labels

Both the manipulator and the controller are marked with several safety and information labels, containing important information about the product. The information is useful 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 41

.

The information labels can contain information in text (English, German, and

French).

Symbols on safety labels

Symbol xx0900000812 xx0900000811

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 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, impact, 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 xx0900000813

Description

See user documentation

Read user documentation for details.

Which manual to read is defined by the symbol:

• No text: Product manual .

• EPS: Application manual - Electronic Position Switches .

Before disassemble, 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 xx0900000808

Brake release

Pressing this button will release the brakes. This means that the robot arm can fall down.





Symbol

1 Safety


Continued

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





43

1 Safety


Continued

Symbol Description

Heat

Risk of heat that can cause burns. (Both signs are used) xx0900000818

!

xx1300001087

1 xx0900000819

3

4

5

2

6

Moving robot

The robot can move unexpectedly.

xx1000001141

2

4

3

1 xx1500002616





Symbol

1 Safety


Continued

Description

Brake release buttons xx0900000820 xx1000001140 xx0900000821

Lifting bolt

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





45

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





2.1 Introduction


2.1 Introduction

General

This chapter contains assembly instructions and information for installing the IRB

4600 Foundry Prime at the working site.

More detailed technical data can be found in the Product specification for the IRB

4600 Foundry Prime, such as:

• Load diagram

• Permitted extra loads (equipment), if any

• Location of extra loads (equipment), if any.


Before any installation work is commenced, it is extremely important that all safety information is 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

If the IRB 4600 Foundry Prime is connected to power, always make sure that the robot is connected to protective earth before starting any installation work.

For more information see:





47


2.2 Installation and operational requirements for Foundry Prime robots

2.2 Installation and operational requirements for Foundry Prime robots

Introduction

Robots with protection type Foundry Prime are specially designed to work in harsh environments. To ensure that the protection offers the best reliability, special measures are required during installation and operation. It is required that the environmental and application conditions are fulfilled and that the special maintenance activities and intervals for the Foundry Prime protected robot are followed.

Fluids in the vicinity of the robot

If fluids that can cause rust formation, for example, water etc., are used in the vicinity of the robot it is required to add rust inhibitor to the fluid or take other measures to prevent rust on unpainted joints or other unprotected surfaces of the robot.

Activity to lubricate gearboxes cavities and gears

Run each axis on high speed at least once per hour. This activity will lubricate the gearbox cavities and gears, which reduces the risk for corrosion due to condensation in the gearboxes.

Pressurized components

The motors, the balancing device, and the serial measurement board cavity must be pressurized on Foundry Prime robots during operation and shut down. The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment.

At the installation of the Foundry Prime robot a pressure sensor and pressure relief valve (not included) must be installed in the air supply system to monitor the supply of air pressure in order to secure a correct pressure. See

Pressurizing equipment on page 49

for equipment specifications.

Note

The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independent of Motors On/Off mode, start-up, and shut down periods.

WARNING

Do not to exceed the maximum pressure of 0.3 bar. If the air pressure exceeds the specified, it can lead to damage to the gearbox or brake failure in the motors which may cause the robot arms to fall down, leading to personal injury or physical damage.







Continued

WARNING

If the pressurized air contains oil, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage.

Note

To secure the supply of air pressure, use a pressure sensor.

Air quality for pressurizing of robot

The air must be dry and clean, such as instrument air. The following table describes the air specifications.

Parameter

Dew point

Solid particle size

Oil content

Air flow

Value

<+2°C at 6 bar

<5 microns

<1 ppm (1 mg/m 3 )

>200 L/min

Pressurizing equipment

ABB recommends a safety valve (if not included) set at 0.4 bar, pressure sensor set at 0.2-0.3 bar or regulator set for maximum 0.3 bar to be attached on the pressure side of the air system.

Example of products:

Equipment

Pressure sensor

Pressure regulator

Description

Festo SDE1-series

Festo LRP-series

Connect air hose to over pressure limiter unit

Note

ABB recommends the air pressure to be set at maximum 0.3 bar.





49



Continued xx1700000565

Precautionary measures

Note

It is strictly forbidden to expose any part of the robot to direct high pressure water jet! The sealing joints between the moving parts on the wrist must not be exposed to high pressure water.

Rebounding high pressure water jet must be avoided. ABB recommends using a tool design with integrated covers that protect the wrist from direct or indirect high pressure water jet.

Note

Make sure that the special Foundry Prime painting of the robot is not broken during testing, installation, or repair work. Use the touch up kit available for

Foundry Prime (article number 3HAC035355-001) to repair any damages in the paint.







Continued

Sensitive points IRB 4600

Illustration shows points that are particularly sensitive to water spray.

A

B

C xx0800000462

A

B

C

Inside lower arm

Cable package

Wrist

Shut-down periods

During shut-down periods the cleaning cell must be ventilated out (aired out). This reduces the risk that moister is sucked into gearboxes during cooling down. It gives the robot the possibility to dry as the rust inhibition effect normally gets reduced after some time.

Ventilate and air out the cell during and after shut-downs:

• The cell must be ventilated during shut-down until the atmospheric humidity in the cell has reached the same level as the surrounding environment.

• Will avoid that humid air is trapped into gearboxes or other cavities due to raised vacuum when cooling down.

• Will give the robot a chance to dry as most rust preventive components in washing detergents have a decaying effect, i.e. the rust preventive effect is reduced after a time. Please refer to the Product Specification of the washing detergent in question for decaying effect. Washing detergent or water without rust inhibitor can give an accelerated corrosion on some robot components.

• The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independent of Motors On/Off mode, start-up and shut down periods .




51


2.3.1 Pre-installation procedure

2.3 Unpacking

2.3.1 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

1

2

3

Action

Make a visual inspection of the packaging and make sure that nothing is damaged.

Remove the packaging.

Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damages are found.

4

5

6

7

8

9

10

11

Clean the unit with a lint-free cloth, if necessary.

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 52

If the robot is not installed directly, it must be stored as described in:

Storage conditions, robot on page 55

Make sure that the expected operating environment of the robot conforms to the specifications as described in:

Operating conditions, robot on page 55

Before taking the robot to its installation site, make sure that the site conforms to:

•

Loads on foundation, robot on page 53

•

Protection classes, robot on page 55

•

Requirements, foundation on page 54

Before moving the robot, please observe the stability of the robot:

Risk of tipping/stability on page 60

When these prerequisites are met, the robot can be taken to its installation site as described in section:

On-site installation on page 61

Install required equipment, if any.

•

Installation of signal lamp (option) on page 84

Weight, robot

The table shows the weight of the robot.

Robot model

IRB 4600 Foundry Prime

Weight

440 kg







Continued

Note

The weight does not include tools and other equipment fitted on the robot.

Loads on foundation, robot

The illustration shows the directions of the robots stress forces.

The directions are valid for all floor mounted, suspended and inverted robots.

T xy

F z

F xy

T z xx1100000521

F xy

F z

T xy

T z

Force in any direction in the XY plane

Force in the Z plane

Bending torque in any direction in the XY plane

Bending torque in the Z plane

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

Force xy

Endurance load (in operation)

±3950 N




Max. load (emergency stop)

±7800 N


53



Continued

Force

Force z

Torque xy

Torque z


4350 ±1700 N

±6350 Nm

±1650 Nm


4350 ±5500 N

±13000 Nm

±3000 Nm

Suspended

Force

Force xy

Force z

Torque xy

Torque z


±3950N

-4350 ±1700N

±6350 Nm

±1650 Nm


±7800 N

-4350 ±5500 N

±13000 Nm

±3000 Nm

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 surface

Maximum tilt

Minimum resonance frequency

0.5 mm Flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from ABB.

The value for levelness aims at the circumstance of the anchoring points in the robot base.

In order to compensate for an uneven surface, the robot can be recalibrated during installation.

If resolver/encoder calibration is changed this will influence the absolute accuracy.

15°

22 Hz

Note

It may affect the manipulator lifetime to have a lower resonance frequency than recommended.

The value is recommended for optimal performance.

Due to foundation stiffness, consider robot mass including equipment.

i

For information about compensating for foundation flexibility, see Application manual - Controller software IRC5 , section Motion Process Mode .

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 25 Hz. 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.







Continued

Storage conditions, robot

The table shows the allowed storage conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient temperature (less than 24 hrs)

Maximum ambient humidity

Value

-25° C

+55° C

+70° C

95% at constant temperature

(gaseous only)

Operating conditions, robot

The table shows the allowed operating conditions for the robot:

Parameter




Value

+5°C

+45°C

100% at constant temperature

(gaseous only)

Protection classes, robot

The table shows the available protection types of the robot, with the corresponding protection class.

Protection type

Manipulator, protection type Foundry Prime

Protection class

IP 67




55


2.3.2 Surface inspection before start-up - Foundry Prime

2.3.2 Surface inspection before start-up - Foundry Prime

Foundry Prime coating

Make sure that the special Foundry Prime painting of the robot arm surfaces is not broken or there have been any other damages during testing and installation.

Even a small collision during installation can destroy the preventive coating and the corrosion barrier is broken. Use the Touch up kit available for Foundry Prime,

3HAC035355-001, to repair damages to paint surfaces.

Pre-installation procedure/ Operation conditions, robot

Parameter




Value

+5°C

+45°C

100% at constant temperature (gaseous only)

Protect attachment bolts and washers at the base

Protect the attachment bolts and washers (M24x100) at the base from physical obstructions and splashes with appropriate shield.





2.3.3 Working range and type of motion

2.3.3 Working range and type of motion

Working range

The figures show the working ranges of the robot variants mounted in different ways.

The extreme positions of the robot arm are specified at the wrist center (dimensions in mm).

Working range, floor mounted

The illustration shows the unrestricted working range for a floor mounted robot.

xx0800000267

Variant

IRB 4600 - 60/2.05

Pos. A

2371 mm

Pos. B

1260 mm

Pos. C

1028 mm

Pos. D

593 mm

Pos. E

1701 mm

Pos. F

2051 mm





57



Continued

Working range, suspended mounted

The illustration shows the unrestricted working range for a suspended mounted robot.

xx0900000055

Variant Pos. A

IRB 4600 - 60/2.05

2371 mm

Pos. B

1260 mm

Pos. C

1028 mm

Pos. D

593 mm

Pos. E

1701 mm

Pos. F

2051 mm







Continued

Turning radius

The turning radius of the robot that is floor or suspended mounted is shown in the figure.

+180°

A

B

-180° xx0800000268

Variant

IRB 4600 - 60/2.05

Pos. A

R2051

Pos. B

R593

Robot motion, IRB 4600-60/2.05

The table specifies the types and ranges of motion in every axes.

Location of motion

Axis 1

Axis 2

Axis 3

Axis 4

Axis 5

Axis 6

Type of motion

Rotation motion

Arm motion

Arm motion

Wrist motion

Bend motion

Turn motion

Range of movement

±180°

+150° / -90°

+75° / -180°

±400°

+120° / -125°

±400°




59


2.3.4 Risk of tipping/stability

2.3.4 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 shipping position is the most stable position.

Do not change the robot position before securing it to the foundation!

Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.

The position of the calibration mark (A) in the figure is approximate and is used as aiming aid.

0°

45°

A

15° xx0800000263

WARNING

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





2.4.1 Lifting robot with roundslings

2.4 On-site installation

2.4.1 Lifting robot with roundslings

Introduction

When lifting the robot use roundslings and an overhead crane.

How to lift suspended mounted robot is described in the lifting instruction delivered with the turning tool art. no. 3HAC034766-001. See

Lifting and turning a suspended mounted robot on page 64

.

Required equipment

Equipment

Overhead crane

Roundslings (2 pcs)

Note

Lifting capacity 1 000 kg (Max load at 90°)

• Lifting capacity/roundsling: 1 000 kg

• Length: 2 m

Lifting

Attach the roundslings as shown in the figure.

xx0800000262

A

B

C

Roundsling put folded in U-shape through the lifting lug

Roundsling put folded in U-shape around gearbox axis 3

Lifting lug







Continued

Lifting instructions

Use this procedure to lift the robot in a safe way.

Action Note

1

CAUTION

The IRB 4600 Foundry Prime robot weighs

440 kg.

All lifting accessories used must be sized accordingly!

2

CAUTION

Attempting to lift the robot in any other position than that recommended may result in the robot tipping over and causing severe damage or injury!

3

WARNING

Personnel must not, under any circumstances, be present under the suspended load!

4 Move the robot to its most stable position.

Detailed in section:

•

Risk of tipping/stability on page 60

5

DANGER

Turn off all:

• electric power supply

• hydraulic pressure supply to the robot, before entering the robot working area.

6

7

8

Attach roundsling A to the lifting lug on the frame, and put folded in a U-shape on either side of the upper arm.

See the figure in:

•

Lifting on page 61

Attach roundsling B at axis 3 gearbox by running it folded in a U-shape around the gearbox.

See the figure in:

•

Lifting on page 61

Make sure the roundslings do not rub against any sharp edges.







Continued

9

Action

When the robot is lifted the roundslings will adjust themselves.

Note

CAUTION

When lifting, the robot will tilt slightly backwards! Be careful not to damage the connection box at the base of the robot!

10 Lift the robot with an overhead crane.

xx0800000291

• A: Area where the connection box can be damaged while lifting.

Lifting capacity:

• See

Required equipment on page 61




63


2.4.2 Lifting and turning a suspended mounted robot

2.4.2 Lifting and turning a suspended mounted robot

Introduction

How to lift and turn the robot to a suspended position using the turning accessory is described in the lifting instruction delivered with the turning accessory. Article numbers for the accessory and the instruction is specified in

Special tools on page 394

. Any additional equipment required is specified in the instruction for the lifting accessory. Contact ABB for more information.

Illustration xx1500002116





2.4.3 Setting the system parameters for a suspended or tilted robot

2.4.3 Setting the system parameters for a suspended or tilted robot

General

The robot is configured for mounting parallel to the floor, without tilting, on delivery.

The method for mounting the robot in a suspended (upside down) or tilted position is basically the same as for floor mounting, but the system parameters that describe the mounting angle (how the robot is oriented relative to the gravity) must be re-defined.

Note

With suspended 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 allowed mounting positions are described in the product specification for the robot. The requirements on the foundation are described in


.

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

If the robot is mounted upside down or tilted (rotated around the y-axis), then the robot base frame and the system parameter Gravity Beta must be redefined.

Gravity

Beta should then be π (+3.141593) if the robot is mounted upside down (suspended).

The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians.





65



Continued

Gravity Alpha

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. It is not supported for IRB 140, IRB 1410, IRB 1600ID, IRB 2400, IRB 4400, IRB 6400R,

IRB 6400 (except for IRB 6400 200/2.5 and IRB 6400 200/2.8), IRB 6600, IRB

6650, IRB 6650S and IRB 7600 (except for IRB 7600 325/3.1).

If the robot does not support Gravity Alpha , then use Gravity Beta along with the recalibration 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

Floor mounted

Suspended mounting

Mounting angle (A°)

0°

180°

Gravity Beta

0.000000 (Default)

3.141593







Continued

Examples of mounting angles tilted around the Y axis ( Gravity Beta ) xx1700000267

A

B

C

Floor mounted

Tilted mounting, mounting angle 15°.

Suspended mounting, mounting angle 180°.





67



Continued

Examples of mounting angles tilted around the X axis ( Gravity Alpha ) xx1700000268

Tilted mounting, mounting angle 15°.

Note

For suspended robots (180°), it is recommended to use Gravity Beta instead of

Gravity Alpha .

Defining the parameter in the IRC5 software

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 .

How to calculate a new value is detailed in

Mounting angles and values on page 66 .

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

The system parameters are redefined in the Configuration Editor , in RobotStudio or on the FlexPendant.





2.4.4 Manually releasing the brakes

2.4.4 Manually releasing the brakes

General

The section below describes how to release the holding brakes of each axis' motor.

This can be done in one of three ways:

• using the push-button when the robot is connected to the controller.

• using the push-button on the robot with an external power supply.

• using an external voltage supply directly on the respective brake.

DANGER

When releasing the holding brakes with push-buttons, the robot must be properly attached!

DANGER

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways!

Make sure no personnel is near or beneath the robot arm!

Using the push-button when the robot is connected to the controller

This procedure details how to release the holding brakes with push-buttons, when the robot is connected to the controller.

1

Action

The internal brake release unit is located at the base of the robot.

Note

2

3

4

The brake release unit is equipped with six buttons for controlling the axes brakes.

The buttons are numbered according to the numbers of the axes.

Release the holding brake on a particular axis by pressing the corresponding button on the push-button unit and keeping it depressed.

The brake will function again as soon as the button is released.

xx0800000272





69



Continued

Using the push-button on the robot with an external power supply

This procedure details how to release the holding brakes with the push-buttons, when the robot is not connected to the controller.

1

Action

Connect an external 24VDC power supply to the connector R1.MP on the robot base.

Note

Note

Be careful not to interchange the 24V and 0V pins!

If they are mixed up, damage can be caused to the brake release unit and the system board!

WARNING

Incorrect connections can cause all brakes to be released simultaneously!

2 Release the holding brake on a particular axis by pressing the corresponding button on the push-button unit and keeping it depressed.

xx0800000269

Connect to connector R1.MP:

• 0V to pin 12

• +24V to pin 11

The brake release unit is equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.

See the previous figure.

3 The brake will function again as soon as the button is released.







Continued

Using an external voltage supply directly on the respective brake

This procedure details how to release the holding brake of a specific axis by supplying external voltage directly on the brake.

1

Action Note

Every axis has a holding brake built into the axis motor. This holding brake may be released by connecting 24VDC power supply directly to one of the connectors in the motor.

Make the connection to the current motor according to the Circuit Diagram.

See chapter

Circuit diagram on page 401 .

DANGER

When power is connected directly to the brake cable, the brake will be released immediately when the power is switched on.

This may cause some unexpected robot movements!

2 Connect an external 24 VDC power supply to the motor, according to the figures.

Axes 1, 2 and 3:

Pos 2: +24 V

Note

Be careful not to interchange the 24V and 0V pins!

If they are mixed up, damage can be caused to the intergrated quenching circuits.

Pos 5: 0 V

WARNING

Incorrect connections can cause all brakes to be released simultaneously!

xx1400001984




71


2.4.5 Orienting and securing the robot

2.4.5 Orienting and securing the robot

Introduction

This section describes how to orient and secure the robot to the foundation or base plate in order to run the robot safely. The requirements made on the foundation are shown in sections

Loads on foundation, robot on page 53

and


.

Hole configuration, base

The illustration shows the hole configuration used when securing the robot.

xx0800000271

C

D

Hole for guide bushing

Rear bolt holes







Continued

Dimension, mounting surface and guide bushing

The figure shows the dimension of the mounting surface and guide bushings.

E

C

Ø60

C

F

Ø0.5 A B

(3X120º) 2.5

2x 1x45º

25

(A)

1.6

D

B B

A A

1

G

216.5

433 ±0.5

G

R

(433±0.5)

(D)

B

(C)

E

F

G

Ø35 +0.024

J8

-0.015

A

1.6

1x45º

10

20 min

M16

A-A xx1700001492

(37)

M16

B-B

3x common zone

Position of the front of the robot

M16 (3 pcs)

Guide bushings (2 pcs)

10

20 min

M16

C-C

30 min

Specification, attachment screws

The table specifies the type of securing screws and washers to be used to secure the robot to the foundation or base plate.

Securing parts/Facts

Securing screws, oiled

Washers

Dimension Note

M16 x 60 (installation directly on foundation)

M16 x 70/80 (installation on foundation or base plate, using guide bushings)

Quality 8.8

6 pcs

200 Nm

17 x 30 x 3 6 pcs





73



Continued

Securing parts/Facts

Guide bushings

Dimension Note

Article number: 21510024-

169, 2 pcs.

Added to the rear bolt holes, to allow the same robot to be re-mounted without program adjustments.

xx1200000885

Level surface requirements xx0300000251

Orienting and securing the robot

Use this procedure to orient and secure the robot.

1

Action

Make sure the installation site for the robot conforms to the specifications in section

Preinstallation procedure on page 52

.

Note

2 Prepare the installation site with attachment holes.

Hole configuration of the base is shown in the figure in:

•

Hole configuration, base on page 72

3

CAUTION


440 kg.


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

6

7

Lift the robot to its installation site.

How to lift the robot is described in section:

•

Lifting robot with roundslings on page 61

Fit two guide bushings to the rear bolts in the base.

Guide the robot gently, using the attachment screws while lowering it into its mounting position.

Make sure the robot base is correctly fitted onto the guide sleeves.







Continued

8

9

Action

Fit the securing screws and washers in the attachment holes of the base.

Tighten the bolts in a criss-cross pattern to ensure that the base is not distorted.

Note

Securing robot on a mounting plate

When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts.

Screw joints must be able to withstand the stress loads defined in section

Loads on foundation, robot on page 53 .




75


2.4.6 Fitting equipment on robot

2.4.6 Fitting equipment on robot

Introduction

The robot features mounting holes for additional equipment.

Access to any of the following mounting holes may be obstructed by any additional cabling, equipment, etc., fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell.

Note

All equipment and cables used on the robot, must be designed and fitted not to damage the robot and/or its parts.

Note

Never drill a hole in the robot without first consulting ABB!

Fitting equipment on robot - Load areas

The shaded area indicates the permitted positions (center of gravity) for any extra equipment fitted in the holes intended for this purpose.

xx0800000275 i

Variant

IRB 4600-60/2.05

Max load A

15 kg

Payload + B = Max 60 kg

Max load B

5 kg i

Max load C

15 kg

Max load A+C Max load D

15 kg 35 kg







Continued

Note

Maximum loads must never be exceeded!

Fitting equipment on base and frame

The illustrations show the fitting holes available for fitting extra equipment on the base and frame of the robot.

xx0800000276

A

B

Attachment holes on base

Center axis 2





77



Continued

Fitting equipment on lower and upper arm

The illustrations show the fitting holes available for fitting extra equipment on the lower and upper arm of the robot.

216 (2x M8 16) 90 (3x M8 16)

2x M8 16

0,3

110

A xx0800000280

A

B

Center axis 4

Center axis 3

B

130

65

3x M8

0,3

16







Continued xx0800000279 i

Variant

60/2.05

A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) G

(mm)

1727 900 See note i

1276 960 135 20

H (mm)

See note

i

J (mm)

237

Position H and measurement C is only applicable to IRB 4600 - 40/2.55 and IRB 4600 - 20/2.50.

Position H and measurement C is only applicable to IRB 4600 - 40/2.55 and IRB 4600 - 20/2.50.

Variant

60/2.05

Attachment screws

4x M8, through

Note

On delivery, all of the extra fitting holes are covered with coated set screws.

Remove these to fit extra equipment. Seal with Mercasol.

Note

If extra equipment is removed, cover up equipment holes with coated set screws.

Seal with Mercasol.







Continued

Fitting equipment on wrist and mounting flange

Extra equipment on wrist, robot versions IRB 4600 -60/2.05

The illustration shows the fitting holes available for fitting extra equipment on the wrist of the robot.

xx0800000277

Note

Do not remove screws indicated in the illustration below!

xx0800000281

A

B

Screws not to be removed! Do not use these holes for fitting equipment on the wrist!

Screw hole intended for swivel fitting.







Continued

Extra equipment on mounting flange, robot versions IRB 4600 -60/2.05

The illustration shows the mechanical interface for the mounting flange.

There are two versions of the mounting flange, differences are shown in the figures.

The mounting flange has through holes with a thread all the way through.

xx0800000282

The mounting flange has through holes with a thread only part way through the hole.

8 H9

+ 0,036

0 8 min.

E

0,05 C D

F

30°

SECTION F-F

5x

60°

6x M10 17 1

0,3 C D E

R 50

F

9 min.

10 xx1600000626

Note

Use attachment screws M10, quality 12.9 and 15 mm used thread length.




81


2.4.7 Surface inspection before start-up - Foundry Prime

2.4.7 Surface inspection before start-up - Foundry Prime

Foundry Prime coating

Make sure that the special Foundry Prime painting of the robot arm surfaces is not broken or there have been any other damages during testing and installation.

Even a small collision during installation can destroy the preventive coating and the corrosion barrier is broken. Use the Touch up kit available for Foundry Prime,

3HAC035355-001, to repair damages to paint surfaces.

Pre-installation procedure/ Operation conditions, robot

Parameter




Value

+5°C

+45°C

100% at constant temperature (gaseous only)

Protect attachment bolts and washers at the base

Protect the attachment bolts and washers (M24x100) at the base from physical obstructions and splashes with appropriate shield.





2.4.8 Loads fitted to the robot, stopping time and braking distances

2.4.8 Loads fitted to the robot, stopping time and braking distances

General

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.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the product specification. The loads must be defined in the software.

• Operating manual - IRC5 with FlexPendant

Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot.




83


2.4.9 Installation of signal lamp (option)

2.4.9 Installation of signal lamp (option)

Signal lamp

See the assembly instruction delivered with the signal lamp.





2.5.1 Axes with restricted working range

2.5 Restricting the working range

2.5.1 Axes with restricted working range

General

When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited.

The working range of the following axes may be restricted:

• Axis 1, hardware (mechanical stop) and software

• Axis 2, software

• Axis 3, software.

This section describes how to install hardware that restricts the working range.

Note

Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures.

WARNING

Remove the mechancial stop bracket if the robots full working range is from a mechanical stop to another mechanical stop. Otherwise the mechanical stop pin will be worn out.

xx1500000253




85


2.5.2 Mechanically restricting the working range of axis 1

2.5.2 Mechanically restricting the working range of axis 1

Mechanically restricting the working range

The information in this section is valid both for the floor and the suspended mounted robot.

The working range of axis 1 is limited by fixed mechanical stops. The working range can be reduced further by adding movable mechanical stops.

The mechanical turning range can be limited in steps of 22.5° from the synchronization position, between values defined in the table. The values differ depending on which design of the gearbox (and base) the robot is equipped with.

Design of gearbox

Type C other design than Type C

Limitation in mechanical turning range, calculated from synchronization position

±126° to ±13.5° in steps of 22.5°

±129° to ±16.5° in steps of 22.5°

Note

The software working range limitations must be adjusted to correspond to the changes in the mechanical limitations of the working range. The system parameters that must be changed ( Upper joint bound and Lower joint bound ) are described in Technical reference manual - System parameters .


Equipment, etc.

Mechanical stop, axis 1

Attachment screw

Washer

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

Art. no.

Note

See

Spare part lists on page 399

.

Includes two additional stop lugs, attachment screws, washers and instruction

See


.

2 pcs/stop lug

Hex socket head cap screw M12x40, quality

8.8-A3F

See


.

2 pcs/lug

13x24x2.5

Content is defined in section

Standard tools on page 393 .

These procedures include references to the tools required.







Continued

Additional stops

The additional stops are fitted as shown in the figure.

A

B

C

D, E xx0800000273

A

B

C

D

E

Movable mechanical stop. Limited to:

• -126° (Type C)

• -129° (other design than Type C)


• +13.5° (Type C)

• +16.5° (other design than Type C)


• -13.5° (Type C)

• -16.5° (other design than Type C)

Attachment screws

Washers

Fitting, mechanical stop axis 1

How to fit the additional mechanical stop to the base is described in the procedure.

Mounting instructions are also supplied with the kit.

1

Action

Determine the position of the stop lugs.

Note

See the figure

Additional stops on page 87

for guidance.







Continued

2

Action Note

Fit the stop lugs firmly with attachment screws and washers according to the figure

Additional stops on page 87 .

Specified in

Required equipment on page 86 .

Tightening torque: 82 Nm

Preparing the robot for working range ±180º

This procedure describes how to prepare the robot for working range ±180º.

Action Note

1

DANGER

Turn off all:



2 Remove the two screws holding the mechanical stop and the bracket.

88

3

4

5

Remove the bracket.

Refit the attachment screws.

Seal and paint the joints that have been opened. Also repair possible damages of the special Foundry Prime paint coat of the robot.

See

Cut the paint or surface on the robot before replacing parts on page 201 .

xx1100000091

A Attachment screw

B Bracket, stop axis 1





2.6.1 Installing an expansion container

2.6 Installing options

2.6.1 Installing an expansion container

Validity of this section

This section is only valid for other design than Type C.

Introduction to the expansion container

The expansion container is needed on suspended robots (other design than Type

C) to make sure that the amount of oil in gearbox axis 1 covers all important parts.

Robots ordered as suspended robots have the expansion container installed on delivery.

Expansion container xx1000000318

F

G

D

E

H

A

B

C

Cover

Attachment screw M6x16, quality 8.8-A2F (5 pcs)

Oil expansion container with cover

Base

O-ring D220x5

Attachment screw M5x20, quality 8.8-A2F and washer (2+2 pcs)

O-ring D1=9.5 D2=1.6

Oil plug (to be removed)







Continued


Equipment

Expansion container

Lifting accessory

Lifting instruction

Grease

O-ring for base cover

Note

Kit including oil.

3HAC034766-001

-

Included with the lifting accessory.

Replace if damaged.

Installing an expansion container

Use this procedure to install the expansion container.

1

2

3

Action Information

Lift the robot using the lifting accessory and place it in suspended position with the base free for installation work.

See

Lifting and turning a suspended mounted robot on page 64

.

Remove the cover and the o-ring from the base .

Remove the two existing attachment screws .

4

5

6

Remove the oil plug from the base.

Apply some grease on the small o-ring and place it in the recess on the expansion container.

Fit a plastic plug in the oil drain hole.

xx1500001958

The screws must be replaced with longer screws.

xx1500001956







Continued

7

Action

Fill oil in expansion container, and press down the VK-cover . Secure with three screws and washers.

Information

8

9

Place the expansion container in the base and place it so the drain holes match.

Secure the expansion container with the attachment screws and washers .

xx1500001957 xx1500001959

Tightening torque 6 Nm.

10 Check the o-ring used on the cover. Replace it if damaged.

11 Refit the cover on the base with its attachment screws .

12 Turn the robot so it is not suspended.

13 Turn the robot to suspended position.

14 Inspect the oil level.

See procedure for suspended robot,

Inspecting oil level, axis 1 gearbox on page 113

.




91


2.7.1 Start of robot in hot environments

2.7 Robot in hot environments

2.7.1 Start of robot in hot environments

Introduction

This procedure describes how to start the robot in a hot environment. This procedure must be performed the first time the robot is started in a hot environment or if it has not been used for some time in a hot environment.

There is a possibility that some overpressure has been built up in the system. This overpressure must be released before starting up the robot.

Releasing overpressure in gearboxes

Use this procedure before the start of the robot in a hot environment to release potential overpressure being built up in gearboxes.

Action Note

1

DANGER

Turn off all:



2

CAUTION

Before approaching the potentially hot robot component, observe the safety information in section

Hot parts may cause burns on page 32

.

3

Note

Before opening the oil plug, make certain that the oil plug is above the oil level. Place the robot accordingly.

4 Open oil plug filling very carefully !

Tip

Note

Open the oil plug just enough for the overpressure to be released.

Hold a cloth or some paper over the oil plug while opening it to prevent surplus oil causing burns or other injuries.

5

6

7

Let the overpressure leave the gearbox.

Refit the oil plug.

Continue releasing the overpressure on all gearboxes.





2.8.1 Start of robot in cold environments

2.8 Robot in cold environments

2.8.1 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 .

1

2

3

Action

Turn off Motion Supervision.

Start the robot.

When the robot has reached normal working temperature, the Motion Supervision can be turned on again.

Note

Robot stopping with other event message

Use this procedure if the robot is not starting.

1

Action

Start the robot with its normal program but with reduced speed.

Note

The speed can be regulated with the

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

3 Work cycles

5 Work cycles

5 Work cycles

5 Work cycles

More than 5 Work cycles

AccSet

20, 20

40, 40

60, 60

100, 100

100, 100

Speed/velocity v100 (100 mm/s) v400 (400 mm/s) v600 (600 mm/s) v1000 (1000 mm/s)

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.




93


2.9.1 Robot cabling and connection points

2.9 Electrical connections

2.9.1 Robot cabling and connection points

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.

Main cable categories

All cables between the robot and controller are divided into the following categories:

Cable category

Robot cables

Description

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 94

.

Customer cables (option) 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.

See the product manual for the controller, see document number in

References on page 10 .

External axes cables (option) Handles power supply to and control of the external axes' motors as well as feedback from the servo system.

See the Application manual - Additional axes and stand alone controller (M2004) , see document number in

References on page 10 .

Robot cables

These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.

Cable sub-category

Robot cable, power

Robot cable, signals

Description Connection point, cabinet

Transfers drive power from the drive units in the control cabinet to the robot motors.

XS1

Transfers resolver data from and power supply to the serial measurement board.

XS2

Connection point, robot

R1.MP

R1.SMB

Robot cable, power

Cable

Robot cable, power: 7 m




Art. no.

3HAC026787-001

3HAC026787-002

3HAC026787-003

3HAC026787-004






2.9.1 Robot cabling and connection points

Continued

Robot cable, signals

Cable

Robot cable signal, shielded: 7 m




Art. no.

3HAC2493-1

3HAC2530-1

3HAC2540-1

3HAC2566-1

Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.

A

B xx1600002016

A

B

Diameter

Diameter x10

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.

xx1600001004




95


2.9.2 Customer connection on robot

2.9.2 Customer connection on robot

Location of customer connection

For the connection of extra equipment to the robot, cables and air hose are integrated into the robot´s cabling, and there is one UTOW71210SH06 and one

UTOW71626SH06 connector on the front part of the upper arm.

The customer connections are located on the robot as shown in the figure.

Customer connection.

xx1700002241

C

D

A

B

Air M16x1.5 (24° cone sealing)

R2.CP

R2.CS

R2.ETHERNET





Customer connections base




A

B

C

D

R1.CP/CS

Air M16x1.5

R1.ETHERNET

R1.SMB

Extra equipment connections

Connections to the:

• air hose ( 3/8") is located on the front part of the upper arm and at the base.

Max. 8 bar. Inner hose diameter: 9.5 mm.

• signal cabling (option) is located on the front of the upper arm.

Number of signals, customer connections R1.CP/CS:

• 23 (50V, 0.5A)

• 9 (300V, 2A). 8 are double crimped in R1.CP/CS and one is only accessible in the robot base.

• 2 DeviceNet or Profibus R1.CP/CS

• One protective ground

Number of signals, customer connections R1.ETHERNET:

• 4 EtherNet R1.ETHERNET

Connection sets

To connect power and signal conductors to the robot base/upper arm connectors, the following parts are recommended.

Connector Art. no.

Content Connection set

PROC1 on base

R1.CP/CS 3HAC16667-1

Connector set on base

R1.CP/CS 3HAC033181-001

• Sockets for cable area of 0.14-2.5

mm²

• Hood foundry

• Hinged frame, hood

• Multicontact-module, female

• Hose coupling

• M12 connector, male





97



Continued

Connection set

Connector Art. no.

R2.CP/R2.CS

R2.CP/R2.CS

3HAC025396-001

Content

• Pins for cable area 0.21 - 0.93

mm²

• Bottle shaped shrinking hose

• Angle shaped shrinking hose





2.9.3 Customer connections on upper arm

2.9.3 Customer connections on upper arm

Customer connections on upper arm

The figure shows the customer connections on the upper arm, including the optional signal lamp that can be fitted to the armhouse.

xx1700002242

A

B

C

D

E

Signal lamp

R3.H1 +, R3.H2 -

R2.CP

R2.CS

R2.ETHERNET

Power supply connections on upper arm

Signal name

CPA

CPB

CPC

CPD

CPE

CPF

CPG

Customer Terminal Controller

Customer Contact on Upper arm, R2

Customer Contact on robot base

(cable between robot and controller not supplied)

XP6.1

R2.CP.A

R1.CP/CS.d1

XP6.2

XP6.3

XP6.4

XP6.1

XP6.2

R2.CP.B

R2.CP.C

R2.CP.D

R2.CP.E

R2.CP.F

R2.CP.G (Earth)

R1.CP/CS.d6

R1.CP/CS.d3

R1.CP/CS.d4

R1.CP/CS.d1

R1.CP/CS.d6

CPH R2.CP.H




R1.CP/CS.d7


99


2.9.3 Customer connections on upper arm

Continued

Signal name

CPJ

CPK





XP6.3

XP6.4

R2.CP.J

R2.CP.K

R1.CP/CS.d3

R1.CP/CS.d4

Signal connection on upper arm

Signal name

CSK

CSL

CSM

CSN

CSP

CSR

CSS

CST

CSA

CSB

CSC

CSD

CSE

CSF

CSG

CSH

CSJ

CSU

CSV

CSW

CSX

CSY

CSZ

XP5.1.5

XP5.1.6

XP5.3.1

XP5.3.2

XP5.3.3

XP5.3.4

XP5.3.5

XP5.3.6

XP5.2.9

XP5.2.10

XP5.2.11

XP5.2.3

XP5.2.4

XP5.1.9

XP5.1.10

XP5.1.11

XP5.1.12

XP5.1.3

XP5.1.4





XP5.1.1

R2.CS.A

R1.CP/CS.b1

XP5.1.2

XP5.2.1

XP5.2.2

R2.CS.B

R2.CS.C

R2.CS.D

R1.CP/CS.b2

R1.CP/CS.b3

R1.CP/CS.b4

R2.CS.E

R2.CS.F

R2.CS.G

R2.CS.H

R2.CS.J

R2.CS.K

R2.CS.L

R2.CS.M

R1.CP/CS.b5

R1.CP/CS.b6

R1.CP/CS.b7

R1.CP/CS.b8

R1.CP/CS.b9

R1.CP/CS.b10

R1.CP/CS.b11

R1.CP/CS.b12

R2.CS.N

R2.CS.P

R2.CS.R

R2.CS.S

R2.CS.T

R2.CS.U

R2.CS.V

R2.CS.W

R2.CS.X

R2.CS.Y

R2.CS.Z

R1.CP/CS.b13

R1.CP/CS.b14

R1.CP/CS.b15

R1.CP/CS.b16

R1.CP/CS.b18

R1.CP/CS.b19

R1.CP/CS.b20

R1.CP/CS.b21

R1.CP/CS.b22

R1.CP/CS.b23

R1.CP/CS.b24





2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application

2.10 Additional installation (Foundry Prime)

2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application

General

Robots delivered with the Foundry Prime protection are specially designed to work in water jet cleaning cells with 100% humidity and alkaline detergent. To ensure that the protection offers the best reliability, some measures are needed during installation of the robot according to the procedures below.

Note

For best reliability, it is also of highest importance that the special maintenance instructions for the Foundry Prime robot are followed and documented.

Commissioning

• Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.

• When turning off an cleaning cell we recommend that the humid air inside a cell is ventilated out, to avoid that the humid air is sucked into e.g. gearboxes due to the raised vacuum when cooled down.

Environmental conditions

Humidity

Washing detergent with pH

100%

<9.0

Washing detergent must contain rust inhibitor and be approved by ABB.

Cleaning bath temperature <60°C, used in a typical waterjet cleaning application at suitable speed.

Air specification for pressurizing of robot

The air must be dry and clean, such as instrument air. Following table details the air specification.

Dew point

Solid particle size

Oil content

Pressure to robot

<+2°C at 6 bar

<5 microns

<1 ppm (1 mg/m3)

0.2 - 0.3 bar

WARNING

If the pressurized air contains oil, it could result in a brake failure in the motors and cause the robot arms to fall down, leding to personal injure or physical damage.







Continued

WARNING

If the air pressure exceeds the specified, it could result in a brake failure in the motors and cause the robot arms to fall down, leding to personal injure or physical damage.

Note

To secure sufficient air pressure, it is recommended to use a pressure sensor.

Pressurize the motors and serial measurement board cavity

The robots are prepared with hoses to the motors and the serial measurement board cavity to enable pressurizing of them.

WARNING

The robot must be pressurized also when it is switch off, to avoid that the humid environmental air is sucked into the motors when cooling down.

1

Action

Connect a compressed air hose to air connector on robot base, see illustration.


2

3

4 xx1500002398

Dimension: G1/8, d=6mm

Protect the screws on the Harting connectors on the robot base from corrosion with Mercasol.

Do this when the controller cables are connected.

Pressurize the robot.

Inspect the air system.

See

Air specification for pressurizing of robot on page 101

for correct pressure.

See

Inspection of air hoses (Foundry

Prime) on page 148

.

Protecting from high pressure water

WARNING


102

No part of the robot are allowed to be exposed to direct high pressure jet of water.

The sealings between the moving parts on the wrist must not be exposed to direct or rebounding high-pressure jet of water.






Continued

Protecting the wrist joints

The sealings between the moving parts on the wrist must not be exposed to direct high-pressure water. We recommend that the gripper include a shield that prevents direct water flush on the sealing surfaces of the wrist. The sealings are pointed out in the illustration below.

A

B

C xx0600003108

A

B

C

Axis 5, bearing support side

Axis 5, bearing gear side

Axis 6, mounting flange - gear house

Protecting the wrist flange from corrosion

The mounting surface on the wrist flange is protected with grease. The joint between the wrist flange and the tool and the screw holes on the wrist flange must be protected.

1

Action

After mounting the tool, clean the following surfaces from grease:

• the visible surface (not painted)

• the rear end of the screw holes and end of screws.


2 Protect these surfaces with Mercasol.




A

B xx0600003109

A screw holes and screws

B unpainted surface


103



Continued

3

Action

Before running the robot in a water jet cleaning cell:

• perform a inspection of the pressure in motors and SMB cavity.


Inspection of air hoses (Foundry Prime) on page 148





2.10.2 Commissioning (Foundry Prime)

2.10.2 Commissioning (Foundry Prime)

General

The following should be taken in consideration when running a robot in a water jet application cell:

CAUTION

Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.

Note

To reduce the risk for corrosion due to condensation in gearboxes, it is required that the robot is running with high speed on each axes at least on one occasion each hour. This is to lubricate the gearbox cavities.

Note

When turning off a cleaning cell we recommend that the humid air is ventilated out from the cell, to avoid that the humid air is sucked into gearboxes for example, due to the raised vacuum when cooled down.




105

This page is intentionally left blank

3 Maintenance

3.1 Introduction

3 Maintenance


Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB

4600 Foundry Prime.

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.


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.

Note

If the IRB 4600 Foundry Prime is connected to power, always make sure that the

IRB 4600 Foundry Prime is connected to protective earth before starting any maintenance work.






107

3 Maintenance

3.2 Introduction for Foundry Prime robots

3.2 Introduction for Foundry Prime robots

Introduction

The Foundry Prime robots are designed for installation and operation in very hard environments. Misuse of the robots, as well as poor installation, cleaning, maintenance, and repair can be harmful for the functioning of the robot.

To eliminate these risks appropriate equipment and procedures are required when installing, cleaning, maintaining, and repairing ABB Foundry Prime robots.

An extended maintenance program including service activities and schedule is required.

Cleaning and maintenance of robots with Foundry Prime protection shall be performed by trained personnel.

Specific maintenance activities and intervals for Foundry Prime

The Foundry Prime robots have specific maintenance activities and intervals compared to standard robots:

• More comprehensive

• More frequent

• Sample activities for check of lubrication

• Conditional - for example, water content in gearbox control/decide replacement intervals

Preventive measures every 6 months secure the uptime of the robot:

• Inspection of oil level in gearboxes

• Surface treatment

• Cable harness

Activity to lubricate gearboxes cavities and gears

Run each axis on high speed at least one occasion per hour. This activity will lubricate the gearbox cavities and gears, which reduce the risk for corrosion due to condensation in gearboxes.

Non-predictable situations

Non-predictable situations can give rise to inspections of the robot. Any damages must be attended to immediately!

Note

Repair damages on painted surfaces as soon as possible. Use the touch-up kit

3HAC035355-001 for Foundry Prime protection.

Warranty claims

Warranty claims for defect products due to misuse or failure to fulfil operational and maintenance requirements will not be approved.




3 Maintenance

3.3.1 Specification of maintenance intervals

3.3 Maintenance schedule

3.3.1 Specification of maintenance intervals

Introduction

The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 4600 Foundry Prime:

• 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 M2004 is further described in the

Operating manual - Service Information System .

Overhaul

Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours.

ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working.

Contact your local ABB Customer Service to get more information.




109

3 Maintenance

3.3.2 Maintenance schedule

3.3.2 Maintenance schedule

General

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!

The inspection intervals do not specify the life of each component.

Values for these are specified in the section

Expected component life on page 112

Note

For best reliability, it is of highest importance that the special maintenance instructions for the Foundry Prime robot are followed and documented.

Activities and intervals, Foundry Prime

The following table specifies the required maintenance activities and intervals for robots with protection type Foundry Prime.

Interval Maintenance activity

Equipment

Inspection Oil level in axis-1 gearbox

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Replacement

Inspection

Inspection

Inspection

Inspection

Oil level in axis-2 gearbox





Surface treatment

Cable harness

(Including rubber blocks and straps)

Cable harness

Air hoses

Information labels

Dampers

Mechanical stop, axis 1

Every:

• 6 months

Every:

• 6 months

Every:

• 6 months

Every:

• 6 months

Every:

• 6 months

Every:

• 6 months

Every:

• 6 months i

Every:

• 6 months

If required ii

If required

ii

Every:

• 6 months

Every:

• 12 months

Every:

• 12 months

Every:

• 12 months





3 Maintenance

3.3.2 Maintenance schedule

Continued

Maintenance activity

Equipment

Analysis Oil gearbox axis 6

Interval

Changing

Changing

Changing iv

iv iv

Oil in axis-1 gearbox



Every:

• 3,000 hours or 6 months, whichever occurs first iii

Every:

• 6,000 hours

Every:

• 6,000 hours

Every:

• 6,000 hours

Changing

Changing

iv iv


Oil in axis-5 & -6 gearbox

Every:

• 12,000 hours

Every:

• 3,000 hours or 6 months, whichever occurs first.

Replacement

Replacement

Battery pack, measurement system of type RMU101 or RMU102 (3-pole battery contact)

36 months or battery low alert v

Battery pack, measurement system with

2-pole battery contact, e.g. DSQC633A

Battery low alert vi

Robot 40,000 hours Overhaul

Overhaul Axis-6 gearbox Every:

• 24 months i

Damage to painted surfaces must be repaired as soon as possible to avoid corrosion.

ii

The warranty does not apply to effects or wear caused by environmental factors.

iii

Analyse the water content in oil in gearbox axis 6 first time after 3,000 hours or 6 months. If the working conditions changes, analyse again after 3,000 hours or 6 months.

iv Before changing oil, always check the oil level. Always analyze the water content in the exchanged oil, according to

Analyzing the water content in gearbox oil on page 190

, to determine the condition of each gearbox.

v

If the water content in oil is more than 3%, analyze the new oil within 2 months. Repeatedly high water content in oil indicates wear of radial sealing in the gearbox.

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced.

The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

See the replacement instruction for more details.

vi The battery low alert (38213

Battery charge low ) is displayed when remaining backup capacity

(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with

FlexPendant for instructions.




111

3 Maintenance

3.3.3 Expected component life

3.3.3 Expected component life

General

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

Note

For expected component life of Foundry Prime robots see

Expected component life - protection type Foundry Prime on page 112 .

Expected component life - protection type Standard

Component

Cable harness

Normal usage i

Expected life

40,000 hours ii

Note

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Cable harness

Extreme usage iii

20,000 hours

ii

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Gearboxes iv

40,000 hours i

Examples of "normal usage" in regard to movement: most material handling applications.

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.

iv Depending on application, the lifetime can vary. The Service Information System (SIS), integrated in the robot software, can be used as a guidance for planning service of gearbox for the individual robot. This applies to gearboxes on axes 1, 2 and 3. The lifetime of gearbox axes 4, 5 and 6 is not calculated by SIS (See the Operating manual - Service Infomation System ) In applications such as

Foundry or Washing the robot can be exposed to chemicals, high temperature or humidity which can have an effect on the lifetime of gearboxes. Contact the local ABB Robotics Service team for more information.

The SIS for an IRC5 system is described in the Operating manual - Service Information System .

Expected component life - protection type Foundry Prime

The demanding nature of using Foundry Prime robots in a washing application, can shorten the life of the robot’s components compared to that of standard robots in a typical robotic application. See

Expected component life - protection type

Standard on page 112 for standard robots. Depending on the actual washing

application, the life of an individual robot can vary or being reduced.

The life of Foundry Prime robots in washing applications will depend on a number of factors. The most important factors are:

• the washing detergent used

• the ambient environment

• installation, maintenance, and repair procedures

• the operation cycle of the robot.




3 Maintenance

3.4.1 Inspecting oil level, axis 1 gearbox

3.4 Inspection activities

3.4.1 Inspecting oil level, axis 1 gearbox

Mounting position of the robot

If the robot is floor mounted, follow the procedures in

Inspecting the gearbox oil level in a floor mounted robot on page 114

.

If the robot is suspended, follow the procedures in

Inspecting the gearbox oil level in a suspended robot on page 116

.


Equipment

Oil plug sealing washer, gearbox

Lubrication oil

Note

3HAC029646-001

See section

Type of lubrication in gearboxes on page 151

.

Standard toolkit Content is defined in section

Standard tools on page 393

.

Other tools and procedures may be required.

See references to these procedures in the step-by-step instructions below.


Additional equipment - Foundry Prime

Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush

Foundry Prime touch up kit

Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol





113

3 Maintenance


Continued

Inspecting the gearbox oil level in a floor mounted robot

Location of oil plugs (floor mounted)

The axis 1 gearbox is located between the frame and base of the robot. The oil plug for inspection is shown in the figure.

Old design : xx0800000304

A

B

Oil plug, inspection

Oil plug, gearbox

Current design :

B

C

A xx1000000669

A

B

C

Oil plug draining, on gearbox

Oil plug filling, on surface for motor flange

Surface for motor flange





3 Maintenance


Continued

Inspecting oil level, axis-1 gearbox (floor mounted)

Use this procedure to inspect the oil level in the axis-1 gearbox, when the robot is floor mounted.

Action Note

1

WARNING

Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section

Safety risks during work with gearbox lubricants (oil or grease) on page 37

.

2

DANGER

Turn off all:



3

4

5

CAUTION

The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let out the excess pressure.

Open the oil plug, inspection .

Old design :

Measure the oil level by looking into the hole of the oil plug inspection.

Required oil level:

• 0 -5 mm, up to the lower edge of the oil plug hole of the oil plug inspection.

See

Location of oil plugs (floor mounted) on page 114 .

A

B xx1200000859

Parts:

A Oil plug inspection

B Approximate oil level





115

3 Maintenance


Continued

6

7

8

9

Action

Current design :

Measure the oil level at the oil plug hole.

Required oil level:

• 35 ± 3 mm below the surface for the motor flange.

The oil level shall only just start to be observed when looking through the oil filling hole. See figure!

Note

Add oil if required.

Refit the oil plug, inspection.

xx1000000824

Parts:

• A: 35 ± 3 mm

• B: Surface for motor flange

• C: Filling hole

• D: Oil level

How to fill oil is described in section:

•

Changing the oil, axis 1 gearbox on floor mounted robots on page 153

Tightening torque:

• 24 Nm

Seal and paint the joints that have been opened. Also repair possible damages of the special Foundry Prime paint coat of the robot. See

Cut the paint or surface on the robot before replacing parts on page 201

.

Inspecting the gearbox oil level in a suspended robot

Location of oil plugs (suspended)

Old design :

A

B xx1200000883

A

B

Oil plug, filling

Oil plug, draining





Current design :

A

3 Maintenance


Continued

C

B xx1000001436

A

B

C

Filling oil plug, on gearbox

Draining oil plug, on surface for motor flange


Inspecting oil level, axis-1 gearbox (suspended robot)

Use this procedure to inspect the oil level in the axis-1 gearbox, when the robot is suspended.

Note

1

If the axis-1 gearbox is filled with an amount of oil suited for an inverted position, the oil level can only be inspected in the inverted position! If the robot was taken down to stand on the floor, the oil level would be above the oil plug hole, which would result in oil leakage if the plug would be opened while robot stands on the floor!

Action Note

WARNING



.





117

3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:



3

CAUTION


4

5

Open the oil plug inspection on the axis 1 gearbox.

See the figure in:

•

Location of oil plugs (floor mounted) on page 114

Required oil level:

• up to the lower edge of the oil plug hole.

Note

The oil plugs on gearbox axis 1 are now on top.

118 xx1100000008

6

7


Refit the oil plug.

Note

Before refitting the oil plug in the gearbox, always replace the oil plug sealing washer with a new one. If not there is a risk of leakage.


•


Tightening torque:

• 3-8 Nm

8 Seal and paint the joints that have been opened. Also repair possible damages of the special Foundry Prime paint coat of the robot. See


.




3 Maintenance

3.4.2 Inspecting the oil level, axis 2 gearbox

3.4.2 Inspecting the oil level, axis 2 gearbox

Location of axis 2 gearbox

The axis 2 gearbox is located in the lower arm rotational center, underneath the motor attachment. The oil plugs are shown in the figure.

xx0800000305

A

B

Oil plug, filling

Oil plug, draining (Quick connect fitting)


Equipment


Lubrication oil

Note

3HAC029646-001

See section


.

Oil plug (Quick connect fitting)

Standard toolkit

For article number see

Spare part lists on page 399 .



.





Equipment

Rust preventive

Art. no.

3HAC034903-001

Note

Mercasol





3 Maintenance


Continued

Equipment

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC026759-001

12340011-116

3HAC035355-001

Note

Inspecting oil level, axis 2 gearbox

Use this procedure to inspect the oil level in the axis 2 gearbox.

Action Note

1

WARNING



.

2

DANGER

Turn off all:



3

CAUTION


4

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling parts.

See


5 Open the oil plug, inspection (location depends on how the robot is mounted).

See the figure in:

•

Location of axis 2 gearbox on page 119

Note

Always open the oil plug on top, depending how the robot is mounted.

6 Measure the oil level at the oil plug hole.

Required oil level:

• 42 mm ± 5 mm below the lower edge of the oil plug hole.





3 Maintenance


Continued

7

8

Action


Refit the oil plug.

Note


Note

How to fill oil is described in section

•

Changing the oil, axis-2 gearbox on page 167

Tightening torque:

• 24 Nm



.




121

3 Maintenance




The axis 3 gearbox is located in the upper arm rotational center, underneath the motor attachment. The oil plug for inspection is shown in the figure.

xx0800000306

A

B

Oil plug, armhouse

Oil plug, gearbox (not visible in this figure)


Equipment

Lubrication oil

Note

See section


.



.





Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush



122

Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol




3 Maintenance


Continued

Inspecting the oil level, axis 3 gearbox


Action Note

1

WARNING



.

2 Move the robot to where the upper arm is placed in a +30° position.

3

DANGER

Turn off all:



4

CAUTION


5

CAUTION


See


6

7

8

9

Open the oil plug, armhouse .

See the figure in:

•



Required oil level:

• oil in the gearbox shall be just below the edge of the oil plug hole.


Refit the oil plug.


•


Tightening torque:

• in armhouse: 10 Nm

• in gearbox: 3 Nm





123

3 Maintenance


Continued

Action

10 Seal and paint the joints that have been opened. Also repair possible damages of the special Foundry Prime paint coat of the robot.

See


Note




3 Maintenance




The axis 4 gearbox is located in the upper armhouse. The oil plug is shown in the figure.

xx0800000307

A Oil plug, for filling and draining


Equipment

Lubrication oil

Standard toolkit

Note

See section


.



.





Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol





125

3 Maintenance


Continued

Inspecting the oil level, axis 4 gearbox


Action Note

1

WARNING



.

2 Move the robot to where the upper arm points straight up and the oil plug hole is on top of the axis 4 gearbox.

3

DANGER

Turn off all:



4

CAUTION


5

CAUTION


See


6 Open the oil plug .

See the figure in:

•


7

8


Required oil level:

• 35 ± 5 mm below the oil plug flange.


9 Refit the oil plug, filling.


•


Tightening torque:

• 10 Nm


See





3 Maintenance

3.4.5 Inspecting oil level, gearbox axes 5 - 6

3.4.5 Inspecting oil level, gearbox axes 5 - 6

Location of gearbox, axes 5-6

The gearbox axes 5-6 is located in the wrist unit. The oil plug is shown in the figure.

The figure shows IRB 4600 -60/2.05

A

B xx0800000308

A

B

Oil plug, tilthouse

Oil plug, wrist (also used as air inlet when draining from oil plug A)


Equipment

Lubrication oil

Note

See section


.



.





Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol





127

3 Maintenance


Continued

Inspecting oil level, gearbox axes 5-6 - wrist 60 kg

Use this procedure to inspect the oil level in gearbox axes 5-6.

Action Note

1

WARNING



.

2 Move the robot to where the upper arm is placed in its calibration position.

3

DANGER

Turn off all:



4

CAUTION


5

CAUTION


See


6

7

Open the oil plug, wrist .

See the figure in:

•

Location of gearbox, axes 5-6 on page 127

Required oil level:

• 3 ±3 mm below the edge of the oil plug hole.

Note

Open the oil plug, tilthouse when inspecting. This will level up oil in axes 5 and 6.

See the figure in:

•

Inspecting oil level, gearbox axes

5 - 6 on page 127

8 Add oil if required.

9 Refit the oil plugs.

How to fill oil is decribed in section:

•

Changing oil, axes-5 and -6 gearboxes on page 181

Tightening torque:

• 10 Nm





3 Maintenance


Continued

Action


See


Note

Inspecting oil level, gearbox axes 5-6 alternative method - wrist 60 kg

Use this procedure to inspect the oil level in gearbox axes 5-6 as an alternative method.

Action Note

1

WARNING



.

2

3

Move the robot to where the upper arm is placed in its calibration position.

Move the upper arm (axis 3) to a horizontal position, then rotate (axis 4) +90°.

This will put the oil plug, wrist on top.

See the figure in:

•


Note

In this position it is not possible to open the oil plug, tilthouse , in order to level up oil in axes 5 and 6!

4

DANGER

Turn off all:



5

CAUTION


6

CAUTION


See






3 Maintenance


Continued

7

Action

Open the oil plug, wrist .

Note

See the figure in:

•


8

9

Required oil level:

• 63 ±3 mm below the edge of the oil plug hole.


10 Refit oil plug, wrist .


See



•


Tightening torque:

• 10 Nm




3 Maintenance

3.4.6 Inspecting the cable harness

3.4.6 Inspecting the cable harness

Location of cable harness

The figure shows the location of the cable harness.

xx0900000012

C

D

E

A

B

F

G

H

Bracket, lower arm

Cable harness

Hole in lower arm

Bracket, lower arm

Cable straps steel (One not visible here)

Bracket, frame

Cable strap plastic, lower arm

Bracket, armhouse


Equipment

Standard toolkit

Note






Circuit diagram See chapter






131

3 Maintenance

3.4.6 Inspecting the cable harness

Continued


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

Inspecting the cable harness

Use this procedure to inspect the cable harness. The inspection points are shown in the figure

Location of cable harness on page 131

Action Note

1

DANGER

Turn off all:



2

3

4

5

6

7

Make an overall visual inspection of the cable harness in order to detect wear or damage.

Check the connectors at the base .

Check the connectors at the armhouse .

Check all brackets and straps are properly attached to the robot.

Replace the cable harness if wear, cracks or damage is detected.

How to replace the cable harness is described in

Repair on page 195 .


See





3 Maintenance

3.4.7 Inspecting information labels

3.4.7 Inspecting information labels

Location of information labels

The figure shows the location of the information labels to be inspected.

xx1000000197

E

F

C

D

A

B

G

H

Warning - Symbol of flash (4 pcs)

Warning - Risk of tipping

Label - Lifting instruction

Warning - "High temperature" (2 pcs)

Label - Max. air pressure

Warning - Brake release unit

Label - Calibration

Label - Suspended robot


Equipment

Labels

Spare part number

See


Note





133

3 Maintenance

3.4.7 Inspecting information labels

Continued

Inspecting labels

Use this procedure to inspect the labels on the robot.

Action Note

1

DANGER

Turn off all:



2 Check all labels.

See the figure in

Location of information labels on page 133

.

3 Replace any missing or damaged labels.




3 Maintenance

3.4.8 Inspecting the mechanical stop pin, axis 1

3.4.8 Inspecting the mechanical stop pin, axis 1

Location of mechanical stop pin, axis 1

The mechanical stop pin is located on the frame as shown in the figure.

A

B xx0800000298

A

B

Fixed stop

Mechanical stop pin, axis 1


Equipment

Mechanical stop pin axis 1

Article number

See


Standard toolkit



Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush

Article number

3HAC034903-001

3HAC026759-001

12340011-116




Note



.


Note

Mercasol


135

3 Maintenance


Continued

Equipment


Article number

3HAC035355-001

Note

Inspection of mechanical stop pin, axis 1

Use this procedure to inspect the mechanical stop pin, axis 1.

Action Note

1

DANGER

Turn off all:



2 Regularly check that the mechanical stop pin is not bent or damaged in any other way.

See the figure in:

•

Location of mechanical stop pin, axis 1 on page 135





3 Maintenance


Continued

3

Action Note

Note

If the mechanical stop pin has been deformed or damaged, all of its mounting parts have to be replaced.

How to replace the stop pin is described in section

Replacing stop pin axis 1 on page 301

.

xx0800000045

Parts:

A Attachment screws

B Bracket

C O-ring (2 pcs) - Not used if bracket (D) is installed.

D Bracket

E Stop pin

4

5

Check that the mechanical stop pin is properly attached.

Check that the mechanical stop pin can move freely in both directions and the bracket works as it is supposed to.

xx1000000222





137

3 Maintenance


Continued

6

Action


See


Note




3 Maintenance

3.4.9 Inspecting additional mechanical stops

3.4.9 Inspecting additional mechanical stops

Location of additional mechanical stops

The figure shows the location of the additional stops.

A

B

C

D, E xx0800000273

A

B

C

D

E


• -126° (Type C)

• -129° (other design than Type C)


• +13.5° (Type C)

• +16.5° (other design than Type C)


• -13.5° (Type C)

• -16.5° (other design than Type C)

Attachment screws

Washers


Equipment etc.

Mechanical stop set, axis 1

Standard toolkit

Note

Includes:

• Stop

• Attachment screws plus washers

• Document for movable mechanical stop

For spare part number see


.



.





3 Maintenance

3.4.9 Inspecting additional mechanical stops

Continued

Equipment etc.

Note




Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

Inspecting additional mechanical stops

Use this procedure to inspect the additional mechanical stops on axis 1.

Action Note

1

DANGER

Turn off all:



2

3

4

5

Check the additional mechanical stops on axis 1 for damage.

See the figure in:

•

Location of additional mechanical stops on page 139

Make sure the stops are properly attached.

Tightening torque:

• 82 Nm

If any damage on stops or attachment screws etc. is detected, the mechanical stops must be replaced!

Attachment screws:

• M12x40, quality 8.8-A3F

• 2 pcs/stop lug seal and paint the joints that have been opened. Also repair possible damages of the special Foundry Prime paint coat of the robot.

See





3 Maintenance

3.4.10 Inspecting dampers

3.4.10 Inspecting dampers

Location of dampers

The figure shows the location of all dampers to be inspected.

xx0800000297

A

B

C

Dampers axis 2

Dampers axis 3

Damper axis 5


Equipment

Damper

Standard toolkit -

Spare part no.

See



Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note



.

Note

Mercasol





141

3 Maintenance

3.4.10 Inspecting dampers

Continued

Inspecting dampers

Use this procedure to inspect the dampers.

Action Note

1

DANGER

Turn off all:



2 Check all dampers for damage or cracks.

3

4

5

Check all dampers for existing impressions larger than 2-3 mm.

Check attachment screws for deformation.

If any damage is detected the damper must be replaced.


See


See the figure in:

•

Location of dampers on page 141




3 Maintenance

3.4.11 Inspecting the leak proof o-ring and pressure relief valves

3.4.11 Inspecting the leak proof o-ring and pressure relief valves

Location of the leak proof o-ring

The pressure relief valves and leak proof o-ring is located as shown in the figure.

A

B

Leak proof o-ring

Relief valve (2 pcs)

Required tools and equipment

Equipment

Standard toolkit

Brush


Leak spray

Article number

3HAC035355-001

Note



Required consumables

Consumable

Rust preventive

Sikaflex 521FC

Loctite 574

Article number

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol





3 Maintenance


Continued

Inspecting the leak proof o-ring and pressure relief valves

Use this procedure to inspect the leak proof o-ring and pressure relief valves.

Action Note

1

DANGER

Turn off all:



2

DANGER

It is important to keep the pressure relief valve open and clean. If the air pressure is stopped up, too much pressure can be built up which can be hazardous.

3 Check if the leak proof o-ring is contaminated or covered with litter.

Clean if necessary.

Note

Use a cloth or a brush.

4 Spray the leak proof o-ring valve with leak spray.

• If leak is found, change the 41 mm oring, according to figure.

Note

Make sure not to lose the small o-ring.

xx1700001174

• Screw

• Cover

• O-ring 6.1 mm

• O-ring 41 mm





3 Maintenance


Continued

5

Action

Check if the pressure relief valves are contaminated or covered with litter.

Clean if necessary.

Note

Note

Use a cloth or a brush.


See


xx1700001178




145

3 Maintenance

3.4.12 Inspecting Signal lamp (option)

3.4.12 Inspecting Signal lamp (option)

Location of signal lamp

Signal lamp is an option.

Located as shown in the figure.

A

B C D xx0800000290

A

B

C

D

Signal lamp

R3.H1 +, R3.H2 -

R2.CP

R2.CS


Equipment

Signal lamp

Standard toolkit

Note

For spare parts no. see Spare parts Spare parts options in Product manual, spare parts - IRB 2600 .







Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol





3 Maintenance

3.4.12 Inspecting Signal lamp (option)

Continued

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling parts. See


.

Inspecting signal lamp

Use this procedure to inspect the function of the signal lamp.

Note

If the signal lamp is damaged, it shall be replaced!

1

2

Action

Check that the signal lamp is lit when motors are put in operation ("MOTORS ON").

Note

If the signal lamp is not lit, continue tracing the fault with the steps below.

3

DANGER

Turn off all:



4

5

6

7

8

Check whether the signal lamp is broken. If so, replace.

Check the cable connections.

Measure the voltage in connectors, motor axis 3.

24V

Check the cabling. If a fault is detected, replace.


See





147

3 Maintenance

3.4.13 Inspection of air hoses (Foundry Prime)

3.4.13 Inspection of air hoses (Foundry Prime)

General

The air hoses on Foundry Prime robots must be inspected for leakage every six months.


Equipment, etc.

Leak detection spray

Pressure gauge

Cut off valve

Procedure

-

-

-

Art. no.

For this test it is recommended that the air supply to the robot has a pressure gauge and a cut-off valve connected.

1

Action Note

Apply compressed air to the air connector on robot base, and raise the pressure with the knob until the correct value is shown on the pressure gauge.

Recommended pressure:

0.2-0.3 bar

2 Close the cut off valve.

3

4

The time is < 5 seconds:

• If the answer is YES : Localize the leakage by following the procedures below.

• If the answer is NO : The system is OK.

Remove the leak testing equipment.

Pressurize by opening the cut off valve.

D C xx1500002399

B A

• A: Air connection robot

• B: Pressure gauge

• C: Cut off valve

• D: Air connection

It should take at least 5 seconds for the pressure to reach 0 bar.





3 Maintenance

3.4.13 Inspection of air hoses (Foundry Prime)

Continued

5

Action

Spray suspected leak areas with leak detection spray.

Note

Note

Bubbles indicate a leak.

6 When the leak is localized: correct the leak.




149

3 Maintenance

3.4.14 Inspection of surface treatment (Foundry Prime)

3.4.14 Inspection of surface treatment (Foundry Prime)

Introduction to inspection of surface treatment

Damage to painted surfaces must be repaired as soon as possible to avoid corrosion. All painted surfaces on the robot must be inspected.


Equipment, etc.

Touch up paint Foundry Prime 2, grey

Note


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Article number

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol. Recommended drying time is 24h.

Inspection and repair of surface treatment

Use this procedure to inspect the surface treatment on Foundry Prime robots.

1

2

Action

Inspect all painted surfaces for damages.

Repair damages as described in the instruction included in the spare part kit.

Information




3 Maintenance

3.5.1 Type of lubrication in gearboxes

3.5 Replacement activities

3.5.1 Type of lubrication in gearboxes

Introduction

This section describes where to find information about the type of lubrication , article number and the amount of lubrication in the specific gearbox. It also describes the equipment needed when working with lubrication.

Type and amount of oil in gearboxes

Information about the type of lubrication , article number as well as the amount in the specific gearbox can be found in Technical reference manual - Lubrication in gearboxes available for registered users on myABB Business Portal, www.myportal.abb.com

.

Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information.

For ABB personnel: Always check ABB Library for the latest revision of the manual

Technical reference manual - Lubrication in gearboxes , in order to always get the latest information of updates about lubrication in gearboxes. A new revision will be published on ABB Library immediately after updates.

Location of gearboxes

The figure shows the location of the gearboxes.

xx0800000311

A Axis-1 gearbox





151

3 Maintenance

3.5.1 Type of lubrication in gearboxes

Continued

D

E

B

C

Axis-2 gearbox

Axis-3 gearbox

Axis-4 gearbox

Axis-5 and -6 gearbox

Equipment

Equipment

Oil dispenser

Note

Includes pump with outlet pipe.

Use the suggested dispenser or a similar one:

• Orion OriCan article number 22590

(pneumatic)

Nipple for quick connect fitting, with o-ring Used on the axis-2 gearbox.

Expansion container, gearbox axis 1 Used when the robot is fitted in a suspended position.




3 Maintenance

3.5.2 Changing the oil, axis 1 gearbox on floor mounted robots

3.5.2 Changing the oil, axis 1 gearbox on floor mounted robots

Floor mounted or suspended robot

Depending on whether the robot is floor mounted or suspended, the method of changing the oil differs.

This section describes how to change the axis-1 gearbox oil in a floor mounted robot. If the robot is suspended, see

Changing the oil, axis-1 gearbox on suspended robots on page 160

.

Location of oil plugs

The axis 1 gearbox is located between the frame and base of the robot.

The oil plugs are shown in the figure.

Old design : xx0800000304

A

B

Oil plug, filling and venting

Oil plug, draining





153

3 Maintenance


Continued

Current design :

B

C

A xx1000000669

A

B

C

Oil draining plug gearbox 1

Oil filling and venting plug for gearbox 1



Equipment


Lubricating oil

Oil collecting vessel

Oil dispenser

Standard toolkit

Note

3HAC029646-001

See section


.

The capacity of the vessel must be sufficient to take the complete amount of oil.

One example of oil dispenser can be found in section:

•




.


Equipment

Rust preventive


154

Art. no.

3HAC034903-001

Note

Mercasol




3 Maintenance


Continued

Equipment

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC026759-001

12340011-116

3HAC035355-001

Note

CAUTION



.

Draining, axis 1 gearbox

Use this procedure to drain the gearbox of oil.

The oil must be sucked out from the gearbox. It is recommended to use a pneumatic oil dispenser to drain oil from the gearbox.

Action Note

1

DANGER

Turn off all:



2

WARNING



.

3

CAUTION






155

3 Maintenance


Continued

4

Action Note

• Put an oil collecting vessel as close as possible to the draining hole of the gearbox.

• Replace oil plug draining quickly with a nipple (M10x1.5) where a draining hose is fitted and connect the oil dispenser .


xx1800001138

5 Remove the plug from the vent hole.

WARNING

If the oil plug for venting is not open when the oil dispenser is working, there is a risk of damaging vital parts in the gearbox!

Note

Draining is time-consuming.

Elapsed time varies depending on the temperature of the oil.


•


Different position due to design differences: xx1800001137

6 Suck out the oil with the oil dispenser.

Note

There will be some oil left in the gear after draining.

xx1800001139





3 Maintenance


Continued

Action Note

7

WARNING

Used oil is hazardous material and must be disposed of in a safe way. See section

Decommissioning on page 381

for more information.

8

9

Remove the oil dispenser.

Refit the oil plug, draining .

Note

Before refitting the oil plug in the gearbox, always replace the oil plug gasket with a new gasket. If not there is a risk of leakage.

Tightening torque:

Other design than Type C : 3-8 Nm

Type C : 24 Nm

10 Refit the oil plug, venting .

xx1800001138


Different position due to design differences: xx1800001137 xx1800001139

11 If the robots paint coat is damaged during the procedure, paint touchup is needed.

See

Inspection and repair of surface treatment on page 150





3 Maintenance


Continued

Filling oil, axis 1 gearbox

Use this procedure to fill the gearbox with oil.

Action

1

Note

DANGER

Turn off all:



2

WARNING


Safety risks during work with gearbox lubricants (oil or grease) on page 37 .

3

CAUTION


4 Open the oil plug, filling .

Different position due to design differences: xx1800001137 xx1800001139





3 Maintenance


Continued

5

6

7

Action

Refill the gearbox with lubrication oil .

Note

The amount of oil to be filled depends on the amount previously being drained.

Note

Where to find type of oil and total amount is detailed in

Type and amount of oil in gearboxes on page 151 .

Inspect the oil level.

Refit the oil plug .

How to inspect the oil level is described in section:

•



Different position due to design differences: xx1800001137

8 Seal and paint the joints that have been opened.

Also repair possible damages of the special

Foundry Prime paint coat of the robot. See


.

xx1800001139




159

3 Maintenance

3.5.3 Changing the oil, axis-1 gearbox on suspended robots

3.5.3 Changing the oil, axis-1 gearbox on suspended robots

Floor mounted or suspended robot

Depending on whether the robot is floor mounted or suspended, the method of changing the oil is different.

How to change oil if the robot is floor mounted, see


.


The axis-1 gearbox is located between the frame and base of the robot. The oil plugs are shown in the figures.

Other design than Type C:

B xx1200000883

A

B

Oil plug, venting

Oil plug, draining and filling

A





Type C:

3 Maintenance


Continued

A

C

B xx1000001436

A

B

C

Oil plug, venting

Oil plug, draining and filling

Motor flange


Equipment


Lubricating oil


Oil dispenser

Note

3HAC029646-001

See section




•


Oil change equipment





3 Maintenance


Continued

Equipment

Hose

Standard toolkit

Note

Used with the oil dispenser



.


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

CAUTION



Draining, axis-1 gearbox


Tip

1

In order to save time, a pneumatic oil dispenser can be used to suck the oil out from the gearbox.

Action Note

DANGER

Turn off all:



2

WARNING



.





3 Maintenance


Continued

Action Note

3

CAUTION


4 Connect the oil dispenser to the oil plug for draining .

See


xx1800001271

5

6

7

Put the end of the hose in an oil collecting vessel .


Open the end plug of the hose.

Open the oil plug, venting .

See

Location of oil plugs on page 160 .

xx1800001272

8 Using a low air pressure, start sucking the oil out from the gearbox with the oil change equipment.

9

WARNING




10 Let the oil drain until the gearbox is empty.

Tip

Note

There will be some oil left in the gearbox after draining. Measure the volume of the drained oil in the vessel.

Make a note how much oil was drained.

The same amount shall later be refilled.





3 Maintenance


Continued

11

12

Action Note

Remove the hose and clean it.

If the robots paint coat is damaged during the procedure, paint touch-up is needed.

See

Inspection and repair of surface treatment on page 150

Filling oil, axis-1 gearbox


Action

1

Note

DANGER

Turn off all:



2

WARNING



3

CAUTION


4 Verify that the hose of the oil change equipment is clean and then fit the quick connection to the oil plug for filling .

xx1800001271

5 Open the oil plug for venting .


164 xx1800001272




3 Maintenance


Continued

6

Action

Prepare oil change equipment with the same amount of lubrication oil that was drained.

Note

Note




7

8

9



•


Disconnect the oil change equipment and put on the protective hood on the oil plug.

Refit the oil plug for venting .

Tightening torque:

• 3-8 Nm

Note






.

Expansion container axis-1 gearbox, suspended mounted robots

When the robot is fitted in a suspended mounted position, an expansion container for oil must be fitted on gearbox axis 1.

xx0900000129

A Expansion container





165

3 Maintenance


Continued

Note

The expansion container is installed on delivery on the robot if ordered as option suspended/inverted mounted. If a floor mounted robot shall be fitted in a suspended mounted position, an expansion container must be installed. See

Installing an expansion container on page 89 .




3 Maintenance

3.5.4 Changing the oil, axis-2 gearbox

3.5.4 Changing the oil, axis-2 gearbox


The axis-2 gearbox is located in the lower arm rotational center, underneath the motor attachment.

Oil plugs are shown in the figure.

xx0800000305

A

B

Oil plug, filling (draining when suspended mounted)

Oil plug, draining (filling when suspended mounted) (Quick connect fitting)


Equipment


Lubricating oil


Nipple (TEMA IF 3820 S06)

Standard toolkit

Note

3HAC029646-001

Information about the oil is found in Technical reference manual - Lubrication in gearboxes .

See



To be fitted on a hose, and then used for draining connected to the quick connect fitting .

See

Location of oil plugs on page 167

.



.





3 Maintenance


Continued


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

CAUTION





Action Note

1

DANGER

Turn off all:



2

WARNING



.

3

CAUTION


4 Either

• connect a nipple to the quick connect fitting in the hole for draining or

• remove the quick connect fitting .

See the figure in:

•






3 Maintenance


Continued

5

Action

Open the oil plug, filling .

Note

See the figure in:

•


6

Note

Drainage will be quicker if the oil plug, filling is removed.

Drain the gearbox oil using an oil collecting vessel .

Note



7

WARNING




8

Note

There will be some oil left in the gearbox after draining.

9 Refit oil plug .

Note


Tightening torque:

• 24 Nm



Action Note

1

DANGER

Turn off all:







169

3 Maintenance


Continued

Action Note

2

WARNING



.

3

CAUTION


4

5

Open oil plug, filling .

Refill the gearbox with lubrication oil .

Note


See the figure in:

•




6

7


Refit oil plug .

Note



•

Inspecting the oil level, axis 2 gearbox on page 119

Tightening torque:

• 24 Nm



.




3 Maintenance




The axis-3 gearbox is located in the upper arm rotational center.

Oil plugs are shown in the figure.

xx0800000306

A

B

Oil plug, armhouse

Oil plug, gearbox (not visible in this figure)


Equipment

Lubricating oil


Oil dispenser

Note

Information about the oil is found in Technical reference manual - Lubrication in gearboxes .

See




•


Funnel xx1200000862





3 Maintenance


Continued

Equipment

Standard toolkit

Note



.


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

CAUTION





There is an alternative method to drain the gearbox. See

Draining - alternative method on page 173

.

1

Action

Move the robot to an upright position as shown in the figure.

Note xx0800000327

• A: Oil collecting vessel





3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:



3

WARNING



4

CAUTION


5 Open the oil plug, armhouse

6

7

Open the oil plug, gearbox and use it as a ventilation hole.


See the figure in:

•


See the figure in:

•


Note



8

WARNING

Used oil is hazardous material and must be disposed of in a proper way. See section Decommissioning for more information.

9 Refit oil plugs.

Tightening torque:



Draining - alternative method

Use this procedure to drain the oil from the gearbox, as an alternative method.

If this method is used, oil must be sucked out of the gearbox using an oil dispenser.

1

Action

Move the upper arm of the robot to a position where the oil plug, gearbox is pointing at the floor.

Note

See the figure in:

•






3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:



3

CAUTION


4

5

6

7

Use an oil dispenser fitted to the oil plug, gearbox to drain the oil.

An example of oil dispenser is detailed in section:

•


See the figure in:

•


Replace the oil plug, gearbox with a nipple where a draining hose is fitted.

Connect the oil dispenser .

See the figure in:

•


One example can be found in section:

•


Open the oil plug, armhouse now pointing upwards and use it as a ventilation hole.

See the figure in:

•


8 Start sucking the oil out from the gearbox with the oil ejector equipment.

For capacity of the vessel see section:

•


9

WARNING

Used oil is hazardous material and must be disposed of in a proper way. See section Decommissioning for more information.

10

Note

There will be some oil left in the gearbox after draining!

WARNING

The oil plug, gearbox must be open when the oil dispenser equipment is used! Otherwise sealings and other parts will be damaged.





3 Maintenance


Continued

11

Action

Refit the oilplugs .



1

Action

Move the upper arm to a position where the wrist is pointing towards the floor as shown in the figure.

Note

Note

See the figure in:

•


Tightening torque:


• in gearbox: 3 Nm xx0800000329

2

DANGER

Turn off all:



3

WARNING



4

CAUTION


5 Open the oil plug, armhouse .

See the figure in:

•






175

3 Maintenance


Continued

6

Action

Refill the gearbox with lubricating oil .

Note



Tip

Use a funnel.

7

8

9

Note


Inspect the

Refit the oil level oil plug .

.

Seal and paint the joints that have been opened.




How to inspect oil is described in section:

•

Inspecting the oil level, axis 3 gearbox on page 122

Tightening torque:






3 Maintenance




The axis-4 gearbox is located in the front of the upper armhouse.

The oil plug is shown in the figure.

xx0800000307

A Oil plug, for filling and draining


Equipment

Lubricating oil


Plastic hose

Note

Where to find information of the type of oil , article number and the amount in the gearbox, see section



Used for venting the gearbox during draining.

A suitable hose would be a hose normally used for compressed air.

Length: minimum 300 mm. Diameter: 5 mm.

Funnel xx1200000862





3 Maintenance


Continued

Equipment

Standard toolkit


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

CAUTION



Draining oil

Note



.

Use this procedure to drain oil from the gearbox.

1

Action

Move the robot to the position shown in the figure.

Note

2

DANGER

Turn off all:



3

WARNING



.

xx0800000328

• A: Oil collecting vessel





Filling oil

3 Maintenance


Continued

Action Note

4

5

6

CAUTION


Open oil plug, draining .

See the figure in:

•



Note

Tip

Insert a compressed air hose approximately

100 mm into the gearbox, to vent the gearbox.

This speeds up the draining significantly.



7

WARNING




8 Refit the oil plug.

Tightening torque: 10 Nm.

Use this procedure to fill oil in the gearbox.

1

Action

Move the upper arm to the position shown in the figure.

Note xx0800000330





179

3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:



3

WARNING



.

4

CAUTION


5 Open the oil plug, filling .

6 Refill the gearbox with

Tip lubricating oil .

See the figure in:

•




Use a funnel.

Note


7

8

Refit the oil plug .



.





3 Maintenance

3.5.7 Changing oil, axes-5 and -6 gearboxes

3.5.7 Changing oil, axes-5 and -6 gearboxes


The axes-5 and -6 gearboxes are located in the wrist unit.

The oil plug is shown in the figure.

The figure shows wrist variant 60 kg

A

B xx0800000308

A

B

Oil plug, tilthouse

Oil plug, wrist unit (also used as air inlet when draining from oil plug A)

Note

The gearboxes for axes-5 and -6 are the same.


Equipment

Lubrication oil


Standard toolkit

Note

Where to find information of the type of oil , article number and the amount in the gearbox, see section:





.


Equipment

Rust preventive

Sikaflex 521FC

Art. no.

3HAC034903-001

3HAC026759-001

Note

Mercasol





3 Maintenance


Continued

Equipment

Loctite 574

Brush


Art. no.

12340011-116

3HAC035355-001

Note

CAUTION



Draining axes-5 and -6 gearbox - wrist 60 kg

Use this procedure to drain oil from the gearbox.

CAUTION


1

2

Action

Move the upper arm to a position where it points downwards.

Note

Move axis 5 to a position where the oil plug, tilthouse points downwards.

The turning disk shall be in a horisontal position.

3

DANGER

Turn off all:



4

WARNING



.

5

6

7

Put an oil collecting vessel under the wrist in order to collect drained oil.


Open the o il plug, tilthouse .

See the figure in:

•


Open the oil plug, wrist (air inlet).

This is done for the ventilation of the gearbox and to fascilitate draining.

See the figure in:

•






3 Maintenance


Continued

8

Action

Drain the gearbox.

Note

9

WARNING




Note



Filling oil axes-5 and -6 gearbox - wrist 60 kg

Use this procedure to fill oil in the gearbox.

CAUTION


1

2

Action Note

Move the upper arm to a position where the oil plug, wrist points upwards.

See the figure in:

•


Move axis-5 to a position where the oil plug, tilthouse points upwards.

See the figure in:

•


3

DANGER

Turn off all:



4

WARNING



.

5 Open oil plug, wrist .

6 Open oil plug, tilthouse .

See the figure in:

•


See the figure in:

•






3 Maintenance


Continued

7

Action

Refill oil using oil plug, wrist .

Note

There will be some oil left in the gearbox after draining.

Note

There will be oil left in the gearbox after draining. Therefore the amount of oil filled will be less than the total amount.

When filling oil in a wrist (60 kg) begin by only filling 1.500 ml. Check oil level. If needed add more oil.

8 Refill the gearbox with lubrication oil .

Note




9

10

Inspect the oil level

Refit both oil plugs.

.



.


•

Inspecting oil level, gearbox axes

5 - 6 on page 127

Tightening torque:

• 10 Nm




3 Maintenance

3.5.8 Replacing SMB battery

3.5.8 Replacing SMB battery

Note

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or

RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.

For an SMB board with 2-pole battery contact, the typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended for longer production breaks with a battery shutdown service routine. See Operating manual - IRC5 with

FlexPendant for instructions.

WARNING

See instructions for batteries,

Safety risks during handling of batteries on page 36

.





185

3 Maintenance


Continued

Location of SMB battery

The SMB battery is located at the base of the robot, as shown in the figure.

DSQC 633A xx0800000322

A

B

C

D

E

SMB battery (2-pole battery contact)

Battery cover

Attachment screws

SMB battery cable

How to arrange the battery cable





3 Maintenance


Continued

RMU 101

A

B xx1300000339

A

B

SMB battery (3-pole battery contact)

Battery cover


Note

There are two variants of SMB units and batteries. One with 2-pole battery contact and one with 3-pole battery contact. The variant with the 3-pole battery contact has longer lifetime for the battery.

It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact!

Equipment

SMB battery pack

Standard toolkit

Circuit diagram

Note

Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved equivalent.

See




See chapter



Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol





3 Maintenance


Continued

CAUTION



Removing SMB battery

Use this procedure to remove the SMB battery.

1

Action

Move the robot to its calibration position.

Note

This is done in order to facilitate the updating of the revolution counter.

2

DANGER

Turn off all:



3

ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit please read the safety information in the section

The unit is sensitive to ESD on page 31

4

CAUTION



.

5 Remove the SMB battery cover .

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards which can result in hazardous failures.

See the figure in

Location of SMB battery on page 186 .

6

7

8

Pull out the SMB battery .

See the figure in


Disconnect the battery cable and remove the battery.

See the figure in


How to dispose of the used SMB battery, see chapter

Decommissioning on page 381 .





3 Maintenance


Continued

Refitting SMB battery

Use this procedure to refit the SMB battery.

Action

1

DANGER

Turn off all:



Note

2

ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit please read the safety information in the section


3

4

5

6

7

Reconnect the battery cable to the SMB battery .

See the figure in


Put the battery unit into its recess while arranging the SMB cables as shown in the figure.

See the figure in


Secure the SMB cover with its attachment screws .

See the figure in


Seal and paint the joints that have been opened.

Also repair possible damages of the special Foundry

Prime paint coat of the robot. See


.

Update the revolution counter.

Detailed in

Updating revolution counters on page 360 .

8

DANGER

Make sure all safety requirements are met when performing the first test run. These are further detailed in the section

First test run may cause injury or damage on page 26 .




189

3 Maintenance

3.6.1 Analyzing the water content in gearbox oil

3.6 Analysis activities

3.6.1 Analyzing the water content in gearbox oil

Analysis of the water content

It is recommended to check for water content in the oil every 12 month.

Effect on gearbox replacement

The table shows what effect the analyze result has on the replacement interval of the gearbox.

1

If: Then....

More than 3% water in oil:

• With more than 3% water content there is a risk for corrosion in the gearbox and reduced viscosity in the oil.

Replacement of gearbox required every two years

A

3%

2 Less than 3% water in oil.

6 12 18 24 30

3000 6000 9000 12000 15000

B

C xx0600003155

• A: Water content in gearbox oil

• B: Months or hours in operation

• C: Replacement of gearbox

Normal replacement interval is required for the gearbox.

A

3%

6 12 18 24 30

3000 6000 9000 12000 15000 xx0600003156

• A: Water content in gearbox oil

• B: Months or hours in operation

B




3 Maintenance

3.7.1 Cleaning the IRB 4600 Foundry Prime

3.7 Cleaning activities

3.7.1 Cleaning the IRB 4600 Foundry Prime

WARNING

Turn off all electrical power supplies to the manipulator before entering its work space.

General

To secure high uptime it is important that the IRB 4600 Foundry Prime is cleaned regularly. The frequency of cleaning depends on the environment in which the product works.

Different cleaning methods are allowed depending on the type of protection of the

IRB 4600 Foundry Prime.

Note

Always verify the protection type of the robot before cleaning.

Oil spills

Oil spills from gearboxes

Use the following procedure if any oil spills are detected that can be suspected to originate from a gearbox.

1 Inspect that the oil level in the suspected gearbox is according to the recommendations, see

Inspection activities on page 113 .

2 Write down the oil level.

3 Inspect the oil level again after, for example, 6 months.

4 If the oil level is decreased then replace the gearbox.

Oil spills discolors painted surfaces

Oil spills on painted surfaces of the robot can result in discoloration.

Note

After all repair and maintenance work involving oil, always wipe the robot clean from all surplus oil.

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.

• Never point the water jet at connectors, joints, sealings, or gaskets.

• Do not use compressed air to clean the robot.





3 Maintenance


Continued

• Never use solvents that are not approved by ABB to clean the robot.

• Do not spray from a distance closer than 0.4 m.

• Do not remove any covers or other protective devices before cleaning the robot.

Cleaning methods

The following table defines what cleaning methods are allowed depending on the protection type.

i

Protection type

Foundry

Prime

Cleaning method

Vacuum cleaner

Yes

Wipe with cloth Rinse with water

Yes. With cleaning detergent approved by ABB, spirit or isopropyl alcohol.

See


.

Yes. It is highly recommended that the water contains a rust-prevention solution.

High pressure water or steam

Yes i

.

It is highly recommended that the water and steam contains rust preventive.

If cleaning detergents are used they must be approved by ABB for

Foundry Prime robots.

See


.

Perform according to section

Cleaning with water and steam on page 192 .

Cleaning with water and steam

Instructions for rinsing with water

ABB robots with protection types Standard , Foundry Plus , Wash , or Foundry Prime can be cleaned by rinsing with water (water cleaner).

1

I

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 700 kN/m

2

(7 bar)

I

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum flow: 20 liters/min

I

Typical tap water pressure and flow

Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus , Wash , or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner.

2

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 2500 kN/m

2

(25 bar)

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum water temperature: 80° C

1

2

See

Cleaning methods on page 192

for exceptions.

See

Cleaning methods on page 192

for exceptions.





3 Maintenance


Continued

Additional cleaning instructions for Foundry Prime robots

Washing detergents

• Only washing detergents approved by ABB shall be used.

• The washing detergent must be cleansed continuously.

• The washing detergent must contain rust inhibitor.

• The detergent pH value and concentration must be checked regularly.

• Allowed pH of the washing detergent is maximum 9.0.

• The user must follow the recommendations regarding detergent concentration and pH value.

• No other additive than water is guaranteed without prior testing or agreement with ABB. Other additives than water may have a harmful effect on the life of the robot and its components.

• Recommendations given by the detergent manufacturer for the specific detergent in question must be followed.

Note

If the pH value or the detergent concentration is varying from its original specification, it can become very corrosive.

Approved cleaners and detergents

All cleaners and detergents must be approved by ABB before use. Contact ABB

Robotics Sales Support to get the latest released list of approved cleaners and detergents.

Temperature of cleaning bath

• Maximum temperature <60ºC.

Ambient temperature must not be higher than +45°C.

Note

Make sure that the special Foundry Prime painting of the robot is not broken during testing, installation, or repair work. Use the touch up kit available for

Foundry Prime (article number 3HAC035355-001) to repair any damages in the paint.

Washing without detergent

If the washing is performed without detergent, the water must contain rust inhibitor.

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.




193


4 Repair

4.1 Introduction

4 Repair


Structure of this chapter

This chapter describes all repair activities recommended for the IRB 4600 Foundry

Prime and any external unit.

It is made up of separate procedures, each describing a specific repair activity.

Each procedure contains all 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.

Otherwise damage to the mechanics and electronics may occur.


The details of the equipment required to perform a specific repair activity are listed in the respective procedures.

The details of equipment are also available in different lists in the chapter

Reference information on page 385

.


There are general safety information and specific safety information. The specific safety information describes the danger and safety risks while performing specific steps in a procedure. Make sure to read through the chapter

Safety on page 17

before commencing any service work.

Note

If the IRB 4600 Foundry Prime is connected to power, always make sure that the

IRB 4600 Foundry Prime is connected to earth before starting any repair work.






195

4 Repair

4.2.1 Performing a leak-down test

4.2 General procedures

4.2.1 Performing a leak-down test

When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.


Equipment, etc.

Leak-down tester

Leak detection spray -

-

Article number Note

Performing a leak-down test

1

2

3

Action

Finish the refitting procedure of the motor or gear in question.

Note

Remove the upper oil plug on the gear and replace it with the leak-down tester.

Regulators, which are included in the leak-down test, may be required.

Use caution, apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer.

Correct value:

0.2-0.25 bar (20-25 kPa)

CAUTION

The pressure must under no circumstance be higher than 0.25 bar (20-25 kPa). Also during the time when the pressure is raised.

4

5

6

7

8

Disconnect the compressed air supply.

Wait for approximately 8-10 minutes and make sure that no pressure loss occurs.

If the compressed air is significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease may occur. This is quite normal.

If any pressure drop occurred, then localize the leak as described in step

7 .

If no pressure drop occurred, then remove the leakdown tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detection spray. Bubbles indicate a leak.

When the leak has been localized, take the necessary measures to correct the leak.




4 Repair

4.2.2 Mounting instructions for bearings

4.2.2 Mounting instructions for bearings

General

This section describes how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.

1

2

3

Action

To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.

Note

Ensure that the parts included in the bearing fitting are free from burrs, grinding waste, and other contamination. Cast components must be free of foundry sand.

Bearing rings, inner rings, and roller elements must not be subjected to direct impact. The roller elements must not be exposed to any stresses during the assembly work.

Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot.

In addition to those instructions, the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange.

1

Action

Tension the bearing gradually until the recommended pre-tension is achieved.

Note

Note

The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence.

2 Make sure the bearing is properly aligned as this will directly affect the durability of the bearing.

Greasing of bearings

Note

This instruction is not valid for solid oil bearings.





197

4 Repair

4.2.2 Mounting instructions for bearings

Continued

The bearings must be greased after assembly according to the following instructions:

• The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

• During operation, the bearing should be filled to 70-80% of the available volume.

• Ensure that grease is handled and stored properly to avoid contamination.

Grease the different types of bearings as following description:

• Grooved ball bearings must be filled with grease from both sides.

• Tapered roller bearings and axial needle bearings must be greased in the split condition.




4 Repair

4.2.3 Mounting instructions for seals

4.2.3 Mounting instructions for seals

General

This section describes how to mount different types of seals.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below describes how to fit rotating seals.

CAUTION

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

• Keep the seal in its original wrappings or protect it well before actual mounting.

• The fitting of seals and gears must be carried out on clean workbenches.

• Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.

1

2

3

4

Action

Check the seal to ensure that:

• The seal is of the correct type (provided with cutting edge).

• There is no damage to the sealing edge (feel with a fingernail).

Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced since it may result in future leakage.

Note

Lubricate the seal with grease just before fitting. (Not too early - there is a risk of dirt and foreign particles adhering to the seal.)

Fill 2/3 of the space between the dust tongue and sealing lip with grease. The rubber coated external diameter must also be greased, unless otherwise specified.

Article number is specified in

Equipment on page 199 .

Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in leakage.

Make sure no grease left on the robot surface.





199

4 Repair

4.2.3 Mounting instructions for seals

Continued

Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.

1

2

3

4

Action

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 compound).

If the flange surfaces are defective, the parts may not be used because leakage could occur.

Clean the surfaces properly in accordance with the recommendations of ABB.

Distribute the sealing compound evenly over the surface, preferably with a brush.

Tighten the screws evenly when fastening the flange joint.

O-rings

The following procedure describes how to fit o-rings.

1

2

3

4

5

Action Note

Ensure that the correct o-ring size is used.

Check the o-ring for surface defects, burrs, shape accuracy, or deformation.

Check the o-ring grooves.

The grooves must be geometrically correct and should be free of pores and contamination.

Defective o-rings may not be used.

Lubricate the o-ring with grease.

Defective o-rings, including damaged or deformed o-rings, may not be used.

Tighten the screws evenly while assembling.

Make sure that no grease is left on the robot surface.




4 Repair

4.2.4 Cut the paint or surface on the robot before replacing parts

4.2.4 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.

When replacing parts on a robot with protection type Foundry Prime, it is important to make sure that after the replacement, no surface without paint is exposed to the aggressive working environment.


Equipment

Sealing compound

Tooling pin

Cleaning agent

Knife

Lint free cloth

Spare parts

Rust preventive

Brush

Touch up paint Foundry Prime /

Foundry Prime 2 / Foundry Prime

3, Grey

3HAC035355-001

Note

Sikaflex 521 FC. Color white.

Width 6-9 mm, made of wood.

Ethanol

Mercasol

The grey touch up paint is used on all Foundry Prime robots, regardless of the original color of the robot.

Removing

1

Action

Cut the paint with a knife in the joint between the part that will be removed and the structure, to avoid that the paint cracks.

Description

2 Carefully grind the paint edge that is left on the structure to a smooth surface.

xx0900000121

Refitting

1

2

Action

Before the parts are refitted, clean the joint so that it is free from oil and grease.

Place the tooling pin in hot water.

Description

Use ethanol on a lint free cloth.





4 Repair

4.2.4 Cut the paint or surface on the robot before replacing parts

Continued

3

Action

Seal all refitted joints with Sikaflex 521FC.

Description

4 Use the tooling pin to even out the surface of the Sikaflex seal.

xx0900000122 xx0900000125

5

6

Wait 15 minutes.

Use Touch up paint Foundry Prime, grey to paint the joint.

Sikaflex 521FC skin dry time (15 minutes).

3HAC035355-001

Note

Always read the instruction in the product data sheet in the paint repair kit for Foundry

Prime.

7 Apply Mercasol on all screw heads and set screws after tightening.




4 Repair

4.2.5 The brake release buttons may be jammed after service work

4.2.5 The brake release buttons may be jammed after service work

Description

The brake release unit has push-buttons for the brake release of each axis motor.

When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting.

DANGER

If the power is turned on while a brake release button is jammed in depressed position, the affected motor brake is released. This may cause serious personal injuries and damage to the robot.

Elimination

1

2

3

To eliminate the danger after service work has been performed inside the SMB recess, follow the procedure below.

4

Action

Make sure the power is turned off.

Remove the push-button guard, if necessary.

Verify that the push-buttons of the brake release unit are working by pressing them down, one by one.

Make sure none of the buttons are jammed in the tube.

If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes.




203

4 Repair

4.3.1 Removing the complete cable harness

4.3 Complete robot

4.3.1 Removing the complete cable harness

Introduction

This procedure describes how to remove the complete cable harness.

How to refit the cable harness is described in section

Refitting the complete cable harness on page 217

.

The removal procedure is presented in the order the work is recommended to be performed. Therefore the order is different in the two procedures removal and refitting of the cable harness. Cross references will make it easy to find what is needed to know as the work continues.

The section Removing the complete cable harness consists of the following parts presented in the order the work is recommended to be performed:

• Removal in the base

Removing cable harness in base on page 207

• Removal in the frame

Removing cable harness in frame on page 212

• Removal in lower arm and armhouse

Removing cable harness in lower arm and armhouse on page 214 .

How to replace the SMB unit, brake release unit and motors can be found in:

• SMB unit

Removing the SMB unit on page 247

• Brake release unit

Removing the brake release board on page 253

• Motors

Removing motors on page 305





4 Repair


Continued

Location of the cable harness

The location of the cable harness in the base, frame and lower arm is shown in the figures.

Cable harness, base and frame.

xx0900000009

E

F

G

A

B

C

D

Cover base

Bracket

Cable harness

Axis-1 motor cable

Axis-2 motor cable

Axis-2 motor

Axis-1 motor





205

4 Repair


Continued

Cable harness, lower arm.

xx0900000012

F

G

H

C

D

A

B

E

Bracket, lower arm

Cable harness

Hole in lower arm

Bracket, lower arm

Cable straps, one not visible here (steel)

Bracket, frame

Cable strap, lower arm (plastic)

Bracket, armhouse


Equipment

Deep well hexagon socket

Standard toolkit

Note

Width 30 mm



.







4 Repair


Continued


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001

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.

1

Action Note

Decide which calibration routine to use for calibrating the robot.

• Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot.

• Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot.

If the robot is to be calibrated with reference calibration:

Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot.

If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible.

Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values.

Creating new values requires possibility to move the robot.

Read more about reference calibration for

Axis Calibration in

Reference calibration routine on page 365

.


Pendulum Calibration in Operating manual - Calibration Pendulum .

If the robot is to be calibrated with fine calibration:

Remove all external cable packages

(DressPack) and tools from the robot.

Removing cable harness in base

Use this procedure to remove the cable harness in the base.

1

Action

Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.

Note





207

4 Repair


Continued

Action

2

DANGER

Turn off all:



3 Disconnect the following connectors on the base cover :

• R1.CP/CS

• R1.MP

• R1.ETHERNET (if used)

Note

Tip

Do not remove the R1.SMB-connector and air hose connector at this stage. It will be easier to remove these two when the cover base has been removed.

xx0900000014

Parts:

• A: R1.CP/CS

• B: R1.MP

• C: Air hose connector

• D: Position of R1.ETHERNET (if used)

• E: R1.SMB

4

CAUTION


See


5 Remove the cover base .


208

A

B xx0800000456

A Base

B Cover base

C Attachment screws

C




4 Repair


Continued

6

7

Action

Disconnect connectors on the brake release unit:

• X8

• X9

• X10

Cut the cable straps securing the battery cable.

Note

8

9

Disconnect the battery cable.

Unscrew the thin nut securing the R1.SMB

connector on the outside of the bracket.

xx0900000099

Parts:

• A: Cable straps (2 pcs)

Tip

Use a deep well hexagon socket, width 30 mm (like the ones used for spark plugs, or similar).

A xx1200000888

10 Unscrew the nut for the air connection on the inside of the bracket.

D

C xx1200000889

A Thin nut, width 30 mm

B R1.SMB

C Bracket

D Air connector

B





209

4 Repair


Continued

11

Action

Remove the screw that secures the bracket and unscrew the three other screws a little just enough to be able to slide the bracket sideways.

Note

12 Remove the bracket by sliding it off the remaining three attachment screws and put it at a 90° angle from the base.

Putting the bracket at a 90° angle facilitates the disconnecting of cables from the bracket.

xx0900000100

Parts:

• A: Screw to be removed

• B: Screws to be unscrewed (3 pcs)

Note xx0900000013

Use caution when performing this procedure in order not to damage cables or other components!

Parts:

• A: Bracket at a 90° angle

• B: Base

13 Remove connectors and air hose connector completely from the bracket :

• R1.CP/CS

• R1.MP

• R1.SMB

• Air hose connector


14

A

B

C

D xx1200000890

Remove the SMB unit from its attachment screws.

Leave the screws in the base.

A R1.CP/CS

B R1.MP

C Air hose connector

D R1.SMB

How to remove the SMB unit is described in section:

•

Removing the SMB unit on page 247





4 Repair


Continued

15

16

Action

Disconnect connectors on the SMB unit:

• R1.SMB1-2

• R1.SMB2-6

• R2.SMB

Disconnect the screen connections of:

• R1.SMB1-2

• R1.SMB2-6

Note

17 Disconnect the earth cables .

A xx0900000035

Parts:

• A: Screen connection (4 pcs) xx0900000015

Parts:

• A: Earth

• B: Distance screws





211

4 Repair


Continued

18

Action

Remove the bracket securing the cable package inside the base on the left side, by following these steps:

• Unscrew the attachment screws just enough to be able to remove the bracket.

• Lift the bracket off the screws.

Note

19 xx0900000018

Parts:

• A: Base

• B: Attachment screws

• C: Bracket

Continue removal of the cable package from the frame.

How to remove the cable package from the frame is described in section

•


Removing cable harness in frame

Use this procedure to remove the cable harness in the frame.

Tip

Before starting this procedure, first remove the cable harness in the base. See

Removing the complete cable harness on page 204

.

Action Note

1

DANGER

Turn off all:



2 Disconnect the motor cables on the axis-1 and axis-2 motors.

How to remove the motor cables is described in section:

•






4 Repair


Continued

Action Note

3

CAUTION


See


4

5

6

Remove the package to the frame.

Cut the bracket cable straps securing the cable securing the cable harness to the frame and lower arm.

Prepare the end of the cable package in the base with tape as shown in the figure.

See the figure in:

•

Location of the cable harness on page 205

See the figure in:

•


Tip

In order to protect the connectors from getting residual grease on the cable harness, put some plastic over them prior to pushing it through the hole in the frame.

F

A

E

7

D

Pull out the cable package through the hole in the frame.

C

B xx1200000886

A Tape

B Connectors to SMB unit and Brake release unit

C R1.CP/CS

D Air hose

E R1.MP

F R1.SMB (Connector bent and taped upwards)

Note


8 Continue the removal of the cable package from the lower arm and armhouse.

How to remove the cable package from the lower arm and armhouse is described in section:

•

Removing cable harness in lower arm and armhouse on page 214





4 Repair


Continued

Removing cable harness in lower arm and armhouse

Use this procedure to remove the cable harness in the lower arm and armhouse.

Tip

Before starting this procedure, first remove the cable harness in the base


and frame


.

Action

1

DANGER

Turn off all:



2 Cut the cable strap on the lower arm.

Note

3

CAUTION


See


See the figure in:

•


(Cable harness, lower arm)





4 Repair


Continued

4

Action

Remove the brackets on the lower arm.

Note

D

C

B

A

5 Remove the bracket on the armhouse.

xx0900000020

Parts:

• A: Bracket, lower arm

• B: Bracket, lower arm

• C: Bracket, armhouse

• D: Cable bracket xx0800000335

Parts:

• A: Tubular shaft unit







215

4 Repair


Continued

6

Action

Remove the cable cover on the armhouse.

Note

7

8 xx0800000338

Parts:

• A: Signal lamp

• B: Bracket

• C: Cable cover, armhouse

Remove signal lamp if used.

Continue the removal of the cable package by disconnecting the motor cables of the axis-3, axis-4, axis-5 and axis-6 motors.

How to remove the motor cables from the axis-3, axis-4, axis-5 and axis-6 motors see section:

•





4 Repair

4.3.2 Refitting the complete cable harness

4.3.2 Refitting the complete cable harness

Introduction

This procedure describes how to refit the complete cable harness.

How to remove the cable harness is described in


.

The refitting procedure is presented in the order the work is recommended to be performed.

Therefore the order is different in the two procedures removal and refitting of the cable harness. Cross references will make it easy to find what is needed to know as the work continues.

The section Refitting the complete cable harness consists of the following parts presented in the order the work is recommended to be performed:

• Refitting in the frame

Refitting the cable harness in the frame on page 220

• Refitting in the base

Refitting the cable harness in the base on page 224

• Refitting in the lower arm and armhouse

Refitting the cable harness in the lower arm and armhouse on page 230

.

How to refit the SMB unit, brake release unit and motors can be found in:

• SMB unit

Refitting the SMB unit on page 249

• Brake release unit

Refitting the brake release board on page 255

• Motors

Refitting motors on page 314





217

4 Repair


Continued

Location of the cable harness

The location of the cable harness in the base, frame and lower arm is shown in the figures.

Cable harness, base and frame.

xx0900000009

F

G

D

E

A

B

C

Cover base

Bracket

Cable harness

Axis-1 motor cable

Axis-2 motor cable

Axis-2 motor

Axis-1 motor





Cable harness, lower arm.

4 Repair



F

G

D

E

H

A

B

C

Bracket, lower arm

Cable harness

Hole in lower arm

Bracket, lower arm

Cable straps, one not visible here (steel)

Bracket, frame

Cable strap, lower arm (plastic)

Bracket, armhouse


Equipment

Deep well hexagon socket

Standard toolkit

Note

Width 30 mm



.



Cable grease Shell Alvania WR2


Equipment

Rust preventive

Art. no.

3HAC034903-001

Note

Mercasol





4 Repair


Continued

Equipment

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC026759-001

12340011-116

3HAC035355-001

Note

CAUTION



Refitting the cable harness in the frame

Use this procedure to refit the cable harness in the frame.

Action Note

1

DANGER

2

3

Turn off all:



Clean the joints that have been opened. See


Apply cable grease on these surfaces:

• cable guide inside the hole

• the part of the cable harness that runs through the cable guide.

Cable grease is specified in:

•


4

Note

Two alternative methods to insert the cable package in frame and base are presented below. Chose one of the methods.





4 Repair


Continued

5

6

Action

Use this procedure when replacing the old cable harness:

Method 1, step 1:

Prepare the end of the cable package in the base with tape as shown in the figure.

Note

A

Tip

F


E


Method 1, step 2:

Push the cable package carefully in through the base and up through the hole in the frame.

D

C

B xx1200000886

A Tape

B Connectors to SMB unit and Brake release unit

C R1.CP/CS

D Air hose

E R1.MP

F R1.SMB (Connector bent and taped upwards)

Note






221

4 Repair


Continued

7

Action


Method 2:

Push the cable harness carefully into the hole in the frame and out of the hole in the base.

Perform the procedure in the following order:

• R1.MP

• R1.CP/CS

• R1.SMB1-2 and R1.SMB3-6

• Air hose.

Note

Note


Tip

8


Use this procedure when fitting a new cable harness:

Without removing the plastic around cables and hose, push the cable harness through the hole in the frame.

Note

Check that cables and air hose are placed as shown in the figure above.

Note






4 Repair


Continued

Action

9

Note

It is vital that the position of the air hose is correct, as shown in the figure!

Note

10 Secure the cover to the frame with its attachment screws.

xx0900000096

Parts:

• A: Cables

• B: Air hose

• C: Hole in frame

• D: Cable guide

• E: Position of the front of the robot

11 xx0900000016

Parts:

• A: Frame

• B: Hole in frame

• C: Cover

Connect the axis-1 and axis-2 motor cables .

How to refit the motor cables is described in section:

•






223

4 Repair


Continued

12

Action

Sort out the different cables the way they later will be fit on the bracket in the base.

Note

13 xx0900000017

Connections:

• A: Earth cables

• B: R1.SMB1-2

• C: R1.SMB3-6

• D: R2.SMB

• E: R1.CP/CS

• F: R1.MP

• G: Air hose

• H: Position of R1.ETHERNET (if used)

• J: R1.SMB

Continue the refitting of the cable harness in the base.

How to refit the cable harness in the base is described in section:

•


Refitting the cable harness in the base

Use this procedure to refit the cable harness in the base.

Tip

1

Before starting this procedure, first refit the cable harness in the frame . See:

•


Action Note

DANGER

Turn off all:







4 Repair


Continued

2

Action

Attach the cable harness to the bracket.

Note

3 Secure the bracket on its attachment screws in the base.

xx0900000098

Parts:

• A: Attachment screw and nut

• B: Bracket

• C: Cable harness

Tip

Perform this in the following order:

• Put the attachment screws in the holes but do not tighten them yet (if they have been removed earlier).

• Place the bracket on the attachment screws.

• Secure the bracket with its attachment screws.

xx0900000018

Parts:

• A: Base

• B: Attachment screws (2 pcs)

• C: Bracket





225

4 Repair


Continued

4

Action

Refit the earth cables .

Note xx0900000015

Parts:

• A: Earth

• B: Distance screws

5

6

Connect the contacts on the SMB unit:

• R1.SMB1-2

• R1.SMB3-6

• R2.SMB

Refit the SMB unit.

How to refit the SMB unit is described in section:

•

Refitting the SMB unit on page 249

7 Refit the cables with the screen connections .

8

Tip

When refitting connectors on the bracket , put it at a 90° angle.

A xx0900000035

Parts:

• A: Screen connections (4 pcs) xx0900000013

Parts:

• A: Bracket

• B: Base





4 Repair


Continued

9

Action

Before refitting the connectors on the bracket, arrange cables and connectors as shown in the figure.

Note

10 Refit the connectors and air hose on the bracket:

• R1.CP/CS


• R1.MP

Tip

Do not refit the R1.SMB-connector and air hose at this stage. It will be easier to refit these two when the bracket has been fitted to the distance screws.

A xx1200000857

A R1.CP/CS

B R1.MP

C Air hose

B C xx0900000017

Connectors:

• A: Earth cables

• B: R1.SMB1-2

• C: R1.SMB3-6

• D: R2.SMB

• E: R1.CP/CS

• F: R1.MP

• G: Air hose

• H: Position of R1.ETHERNET (if used)

• J: R1.SMB





227

4 Repair


Continued

11

Action

Secure the bracket on the distance screws.

Note

A

12

13

Reconnect connectors on the brake release unit:

• X8

• X9

• X10

Refit the R1.SMB-connector on the bracket.

xx1200000887

A Base

B Distance screw

C Attachment screw

D Bracket

D

Tip

Use a deep well hexagon socket, width 30 mm (like the ones used for spark plugs, or similar).

C

B

A xx1200000888

14 Refit the air hose connector on the bracket.

D

C xx1200000889

A Thin nut, width 30 mm

B R1.SMB

C Bracket

D Air connector

B

Note

Check that there is no leakage from the air hose.

15 Reconnect the battery cable.





4 Repair


Continued

16

Action

Secure the battery cable with cable straps .

Note

17 Use caution when pushing the base cover into position while at the same time checking that no cables are damaged.

xx0900000099

Parts:

• A: Cable straps (2 pcs)

A

B

18

19

C xx0800000456

Parts:

• A: Base

• B: Base cover

• C: Attachment screws (6 pcs)

Secure the base cover with its attachment screws.

Refit the bracket on the frame.

See the figure in:

•


20

21

Refit the cable straps harness to the frame.

securing the cable See the figure in:

•


Continue the refitting of the cable package on lower arm and armhouse.

How to refit the cable harness on the lower arm and armhouse is described in section:

•






4 Repair


Continued

Refitting the cable harness in the lower arm and armhouse

Use this procedure to refit the cable harness in the lower arm and armhouse .

Tip

Before starting this procedure, first refit the cable harness in the frame and base .

See:

•


•


Note Action

1

DANGER

Turn off all:



2 Secure the brackets on the lower arm.

D

C

B

A

3

4

Refit the cable straps securing the cable harness to the lower arm.

xx0900000020

Parts:

• A: Bracket, lower arm

• B: Bracket, lower arm


• D: Cable bracket

See the figure in:

•


(Cable harness, lower arm)

Push the cable harness carefully into the armhouse.





4 Repair


Continued

5

Action

Secure the bracket, armhouse with its attachment screws.

Note

6 Secure the bracket to the armhouse with its attachment screws.

xx0800000335

Parts:




7

8

9

Reconnect the axis-3, axis-4, axis-5 and axis-6 motor cables .

xx0800000338

Parts:

• A: Signal lamp

• B: Bracket, armhouse

• C: Cable bracket

How to connect the axis-3, axis-4, axis-5 and axis-6 motor cables, see:

•




.

Recalibrate the robot.

Pendulum Calibration is described in Operating manual - Calibration Pendulum , enclosed with the calibration tools.

Axis Calibration is described in

Calibrating with Axis Calibration method on page 364 .

General calibration information is included in section


.





4 Repair


Continued

Action

10

WARNING

The cover on the armhouse must be fitted when the robot is running. It is a vital part for the stability of the robot.

Note

11

DANGER






4 Repair

4.3.3 Replacement of air nipples and hoses (Foundry Prime)

4.3.3 Replacement of air nipples and hoses (Foundry Prime)

Function

The pressure inside the areas A and B are 0.2 - 0.3 bar .

xx1100000047


Equipment

Standard toolkit

Note






Loctite 577

Rust preventive

12691907-1

3HAC026621-001





4 Repair


Continued

Equipment

Brush


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


-

Note

Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001

Note

Make sure that the special Foundry Prime painting of the robot is not broke during testing, installation or repair work. Use touch up kit available for Foundry Prime art. no. 3HAC035355-001 to repair the damage paint coat see section


.

CAUTION







4 Repair


Continued

Replacing air hoses and nipples

The illustration show the routing of the pressure hoses on a IRB 4600 Foundry

Prime robot.

xx1100000049





235

4 Repair


Continued

Lower arm

A

B

Motor 1 xx1100000051

A

B

C

Pneumatic hose - Foundry Prime 360 mm




1

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before entering the workspace of the manipulator.

Also read the safety sections:

•

Safety risks related to pneumatic/hydraulic systems on page 33

•

Risks associated with live electric parts on page 29

•

Safety risks during installation and service work on robots on page 23

2 Remove hose, and remove the straight fitting from the manipulator base.

Motor 2

C

Cover 3-6


236 xx1500002400




4 Repair


Continued

3

Action

Remove the hose protection from motor

1 and 2. Use standard tools.

Information

4 Remove the hoses from the elbow fittings. No tools needed.

xx1100000053 xx1100000054





237

4 Repair


Continued

5

Action

Remove the elbow fittings. Use standard tools

Information

6 Remove hoses from the straight fittings on the cover at the frame. No tools needed.

xx1100000055

7 Remove the straight fittings on the cover at the frame. Use standard tools.

xx1100000056





4 Repair


Continued

8

Action

Remove the Pneumatic hose - Foundry

Prime 2500 mm from the upper elbowfitting.

Information

9 Remove the upper elbow fitting.

xx1100000059 xx1100000060





239

4 Repair


Continued

10

Action

Remove the nuts (B) on all the hose clamps (A). Use standard tools.

Note

It is important to maintain the position of the hoses and the hose clamps. Use a cable strap to secure the position of the rubber blocks.

Information

11 Remove all hose clamps (A) from the lower arm.

xx1100000058

12 Remove the Pneumatic hose - Foundry

Prime 2500 mm from the upper arm.

xx1100000057





4 Repair


Continued

Refitting air hoses and nipples

Action

1

Note

Apply rust preventive around all dismantled covers and attachment screws with a brush.

Information

2

Note

Always apply rust preventive (Mercasol) on covers, attachment plates and screws after refitting these components.

3 Refit the straight fitting on the manipulator base. Apply Loctite 577 on the thread. Use standard tools.

xx1500002401





241

4 Repair


Continued

4

Action

Refit the upper elbow fitting. Apply

Loctite 577 on the thread. Use standard tools.

Information

5 Refit the upper hose in the elbowfitting.

xx1100000061 xx1100000062





4 Repair


Continued

6

Action

Refit all hose clamps

CAUTION

The position of the hoses and the hose clamps is essential. Changedposition can cause wear on the hoses.

Information

7 Refit the elbow fittings on the motors. Apply Loctite 577 on the thread.

Use standard tools.

xx1100000066

8 Refit the hose on the elbow fitting.

xx1100000068





243

4 Repair


Continued

9

Action

Refit the hose protection on motor

1 and 2. Use standard tools.

Information

10

11

Refit the straight fittings on the cover at the frame. Apply Loctite 577 on the thread. Use standard tools.

Refit the hoses on the straight fittings on the cover at the frame.

xx1100000069

244 xx1100000070




4 Repair

4.3.4 Replacing SMB unit

4.3.4 Replacing SMB unit

Location of SMB unit

The SMB unit (SMB = Serial measurement board) is located in the base below the brake release unit, as shown in the figure.

xx0800000466

E

F

G

A

B

C

D

R1.SMB3-6

R1.SMB1-2

R2.SMB

SMB unit

Attachment screws M6x16 quality 8.8-A2F (2 pcs)

Brake release unit

Bracket


Note

There are different variants of SMB units and batteries. The variant with the

3-pole battery contact (RMU) has longer lifetime for the battery.

It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact!

Equipment

Standard toolkit

Note



.





4 Repair


Continued

Equipment Note



SMB unit For spare part no. see chapter Spare parts, section:

•



Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001




1

Action




Note







Axis Calibration in


.










4 Repair


Continued

Removing the SMB unit

Use this procedure to remove the SMB unit.

1

Action


Note

2

DANGER

Turn off all:



3

CAUTION


See


4 Remove the base cover .

CAUTION



C

B

5 Cut the cable straps securing the battery cable.

A xx0900000103

Parts:

A Attachment screws (6 pcs)

B Base cover

C Cable straps, securing the battery cable (2 pcs)





247

4 Repair


Continued

6

Action

Remove the screw that secures the bracket and unscrew the three other screws a little just enough to be able to slide the bracket sideways.

Note

Note

It is not needed to remove these three screws.

7 xx0900000100

Parts:

A Screw to be removed

B Screws to be unscrewed a little (3 pcs)

Remove the bracket by sliding it off the remaining three attachment screws and put it at a 90° angle from the base.

Putting the bracket at a 90° angle facilitates the disconnecting of cables from the bracket.

Cable harness can stay connected to all connectors except to the SMB unit.

8

Note

Use caution when performing this procedure order not to damage cables or other components!

xx0900000013

Parts:

A Bracket at a 90° angle

B Base

Disconnect cable clamps.

9

10

Unscrew the attachment screws securing the SMB unit just enough to be able to remove the SMB unit.

Remove the SMB unit.

A xx0900000035

Parts:

A Cable clamps

See the figure in:

•

Location of SMB unit on page 245





11

Action

Disconnect the battery cable by pressing down the upper lip of the R1.G connector to release the lock while pulling the connector upwards.

Note

4 Repair



12 Disconnect the remaining connectors on the SMB unit:

• R1.SMB1-2

• R1.SMB3-6

• R2.SMB

See the figure in:

•


Refitting the SMB unit

Use this procedure to refit the SMB unit.

Action

1

DANGER

2

3

Turn off all:





Reconnect contacts on the SMB unit:

• R1.SMB1-2

• R1.SMB3-6

• R2.SMB

• Battery cable R1.G (X3) Make sure the lock snaps into place during refitting.

Note xx1700000994

4

5

Place the SMB unit on its attachment screws .

Secure the SMB unit with its attachment screws.

See the figure in:

•






4 Repair


Continued

6

Action

Refit the cable clamps .

Note

7

A xx0900000035

Parts:

A Cable clamps

Put back the cable harness in the base and refit the bracket on the distance screws.

See the figure in:

•


Note

Use caution when performing this procedure order not to damage cables or other components!

8

9

10

Secure the battery cable with cable straps.

Use caution when pushing the base cover into position while at the same time checking that no cables are damaged.

Secure the base cover with the attachment screws.

A

B



.

C xx0800000456

Parts:

A Attachment screws (6 pcs)

B Base cover

C Base





4 Repair


Continued

12

Action


13

DANGER


First test run may cause injury or damage on page 26

.

Note





Calibration on page 353 .




251

4 Repair

4.3.5 Replacing the brake release board

4.3.5 Replacing the brake release board

Location of brake release board

The brake release board is located as shown in the figure.

xx0900000101

A Brake release board

Connectors on push-button board

The connectors X8, X9 and X10 are placed on the push-button board as shown in the figure below.

X9

X8

X10 xx1700000978





4 Repair


Continued


Equipment

Brake release board

Standard toolkit

3HAC065020-001

3HAC062021-001 i ii

Note

DSQC1050

DSQC1052



.

i


ii


Valid for robots that are equipped with motors of Type A and Type B (see Product manual, spare parts - IRB 4600 ).

Includes brake release board and harness.

Valid for robots that are equipped with motors of Type B (see Product manual, spare parts - IRB

4600 ).

Includes brake release board and harness.


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

Removing the brake release board

Use this procedure to remove the brake release board.

Action Note

1

DANGER

Turn off all:



2

ELECTROSTATIC DISCHARGE

(ESD)

The unit is sensitive to ESD. Before handling the unit read the safety information in section






253

4 Repair


Continued

Action Note

3

CAUTION


See


4 Remove the push button guard from the

SMB cover.

The guard must be removed to ensure a correct refitting of the brake release board.

5 Remove the base cover .

CAUTION



A

B

6

7

Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board.

Disconnect connectors X8, X9 and X10 from the brake release board.

C xx0800000456

Parts:

A Base

B Base cover

C Attachment screws M6x16 quality

8.8-A2F (6 pcs)

X9

X8

X10

8

9

Remove the nuts securing the brake release board.

Remove the brake release board.

xx1700000978





4 Repair


Continued

Refitting the brake release board

Use this procedure to refit the brake release board.

Action Note

1

DANGER

Turn off all:



2

ELECTROSTATIC DISCHARGE

(ESD)

The unit is sensitive to ESD. Before handling the unit read the safety information in section


3

4

5



Secure the brake release board to the bracket with its nuts with flange .

Maximum tightening torque: 5 Nm.

See the figure in:

•

Location of brake release board on page 252

Reconnect connectors X8 , X9 and X10 to the brake release board.

Be careful not to damage the sockets or pins.

Make sure the connector and its locking arms are snapped down properly.

X9

X8

X10

6 Verify that the robot cabling is positioned correctly, according to previously taken picture/notes.

WARNING

Screened cables must not get in contact with the brake release board after installation.

Eliminate all risks of contact between screened cables and the brake release board.

xx1700000978





255

4 Repair


Continued

7

Action

Use caution when pushing the base cover into position while at the same time checking that no cables are damaged.

Note

A

B

8 Secure the base cover with its attachment screws .

9

WARNING

Before continuing any service work, follow the safety procedure in section

The brake release buttons may be jammed after service work on page 203

!

C xx0800000456

Parts:

A Base

B Base cover

C Attachment screws M6x16 quality

8.8-A2F (6 pcs)

10

11

12

Refit the push button guard to the SMB cover.

Press the push buttons 1 to 6, one at a time, to make sure that the buttons are moving freely and do not stay in any locked position.


See


.

13

DANGER






4 Repair

4.3.6 Replacing the base

4.3.6 Replacing the base

Location of base and complete arm system

The complete arm system is defined as:

• complete upper arm (includes: wrist unit, tubular shaft unit and armhouse)

• lower arm

• frame

• axis-1 gearbox

The location of the base and the complete arm system is shown in the figure.

xx0800000345

C

D

A

B

E

F

Base

Frame

Lower arm

Arm house (part of complete upper arm)

Tubular shaft unit (part of complete upper arm)

Wrist unit (part of complete upper arm)


Equipment

Roundslings -

Article number

Support legs

Guide pin, M8x150

3HAC15535-1

3HAC15520-2




Note

Length: 2 m (2 pcs), 1.5 m (1 pcs)

Lifting capacity: 1,000 kg.

3 pcs

Always use guide pins in pairs.


257

4 Repair


Continued

Equipment

Lifting eye

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

Cleaning agent -

-


M8

3 pcs




Flange sealant 12340011-116

Loctite 7063

For cleaning.

Loctite 574

For sealing.


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001




1

Action Note










Axis Calibration in


.







4 Repair


Continued

Action




Note

Removing the base

Use this procedure to remove the complete arm system from the base.

1

2

Action


Note

Jog the robot to:

• Axis 1: 0 °

• Axis 2: 0°

• Axis 3: -10°

• Axis 4: 0°

• Axis 5: 0°

• Axis 6: 0°

3

DANGER

Turn off all:



4

CAUTION


See


5 Drain the axis-1 gearbox.

Note



How to drain oil is detailed in section

•


6 Remove the cable harness in the base, the frame and the lower arm of the robot.

How to remove the cable harness in base and frame is detailed in sections:

•

Removing cable harness in base on page 207

Tip

Wrap up the cabling against the frame to keep it undamaged during the remaining work.

•


•






4 Repair


Continued

7

Action Note

Secure the robot with roundslings in an overhead crane.

Stretch the roundslings so that the robot weight is secured when removing foundation bolts in next step.

Dimensions are specified in


.

B

C

A

8

CAUTION


440 kg.


9

10

Remove the bolts that secure the robot to the foundation.

Lift the robot and fit three support legs to the robot base, using bolts, washers and nuts.

xx1100000582

A Roundsling 1.5 m

B Roundsling 2 m

C Roundsling 2 m

DANGER

Working underneath the manipulator without safely securing the support legs between the robot base and the foundation will result in serious or fatal injury.

Make sure the robot is stable and safely secured to the foundation via the support legs, before working underneath the robot.

Keep the lifting accessories stretched for extra safety precautions.

xx1800000874





11

Action

Lower the robot and secure the support legs to the foundation, using bolts and washers.

Note

4 Repair



12 Foundry Prime robots:

Cut the paint with a knife in the joint between the motor and the structure in order to avoid that the paint cracks.

The figure shows the principal method.

CAUTION


See


xx0900000121

13 Remove the cover plate at the bottom of the base.

xx1800000879

14

15

Remove the base attachment screws and washers.

Fit two guide pins in opposite holes in the axis-1 gearbox.

Guide pin, M8x150: 3HAC15520-2


xx1800000883





261

4 Repair


Continued

Action

16

CAUTION

The arm system and axis-1 gearbox weighs

380 kg together.

All lifting accessories must be sized accordingly.

Note

17 Lift away the robot arm system.

Remove the guide pins, if the arm system is about to be laid down on the floor. See

Illustration of robot put down on its side on page 328

.

xx1800000884

18

CAUTION

The weight of the base is 49 kg

All lifting accessories used must be sized accordingly.

19 Fit three lifting eyes to the base and secure with roundslings in an overhead crane or similar.

Lifting eye: M8

20 Remove the support legs attachments screws and remove the base from the support legs.

xx1800000931 xx1800000885





4 Repair


Continued

Refitting the base

Use this procedure to refit the complete arm system to the base.

Action Note

1

CAUTION

The weight of the base is 49 kg


2

3

Fit three lifting eyes to the base and secure with roundslings in an overhead crane or similar.

Lifting eye: M8

Fit the new base to the support legs and secure with the attachment screws.

xx1800000885

4

5



Remove residues of old Loctite and other contaminations from surfaces before applying new Loctite 574.

Tip

Use Loctite 7063 (or similar) for cleaning.





263

4 Repair


Continued

6

Action

Apply Loctite 574 around the screw holes on the axis-1 gearbox as shown in the figure.

Note xx0800000353

Parts

A Loctite 574

B Screw hole in axis-1 gearbox

C Axis-1 gearbox

7

CAUTION

The arm system and axis-1 gearbox weighs

380 kg together.

All lifting accessories must be sized accordingly.

8

9

Lift the arm system to the mounting site.

Fit two guide pins in opposite holes in the axis-1 gearbox.



xx1800000932





4 Repair


Continued

10

Action Note

Lower the arm system against the base and secure with the attachment screws and washers .

Attachment screws: M8x40 quality Steel

12.9 Gleitmo and washers (24+24 pcs).


xx1800000882

Valid for Type C:

11

12

Apply some grease to the o-ring and refit the o-ring between the cover and base.

Refit the cover plate at the bottom of the base with its attachment screws.

Attachment screws: M6x16 quality 8.8-

A2F (5 pcs)

13 Remove the screws that secure the support legs to the foundation.

DANGER

Stretch the roundslings to make sure that the robot weight is secured.

xx1800000879 xx1800000875





265

4 Repair


Continued

14

Action

Lift the complete robot and remove the support legs from the base.

Note xx1800000874

15

16

17

Lower the robot and secure it to the foundation.

See

Orienting and securing the robot on page 72 .



.







18

DANGER



.




4 Repair

4.4.1 Replacing the complete upper arm

4.4 Upper arm

4.4.1 Replacing the complete upper arm

Location of the complete upper arm

The complete upper arm is located as shown in the figure.

xx0800000337

A

B

C

D

E

Upper arm

Lower arm

Attachment screws M8x40 quality steel 12.9 Gleitmo (19 pcs)

Washers quality steel 8.4x13x1.5 (19 pcs)

Axis-2 gearbox


Equipment

Armhouse

Note

For spare parts no. see Spare parts Upper arm

(2.05/2.50/2.55) in Product manual, spare parts - IRB 2600 .





4 Repair


Continued

Equipment

Tubular shaft unit

Rotating lifting point

Note



2 pcs. Dimension: M8.

Example: Gunnebo RLP GrabiQ M8-10.

xx1100000564

Washer

Roundslings

Screws

Guide pins

Standard toolkit

Required if the screw in the rotating lifting point bottoms.

Inner diameter: 12 mm. Outer diameter: min. 23 mm. Thickness: enough to prevent the screw in the rotating lifting point to bottom.

3 pcs.

Length: 1.5 m.

Lifting capacity: 500 kg.

2 pcs. Used to prevent the roundsling at the wrist from sliding.

Dimension:

• M8. Length: 70 mm. Quality: 8.8. (IRB

4600 - 60/2.05

M8 (2 pcs)






Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol





4 Repair


Continued




1

Action Note










Axis Calibration in


.






CAUTION



.

Removing the complete upper arm

Use this procedure to remove the complete upper arm. This procedure can be done without draining the axis 3 gearbox.

1

2

Action


Run the robot to the position shown in the figure.

The robot must be floor mounted and the upper arm must be horizontally positioned.

Note xx0800000336





269

4 Repair


Continued

Action Note

3

DANGER

Turn off all:



4

CAUTION

The weight of the complete upper arm (including the wrist) is 140 kg


5

6

Attach the lifting accessories to the upper arm.

See

Attaching the lifting accessories to the upper arm on page 272 .

Unload the weight of the upper arm by stretching the roundslings.

Tip

Turn on the power temporarily and release the brakes of axis 3 to rest the weight onto the roundslings.

7

DANGER

Turn off all:



8

CAUTION


See


9 Disconnect all motor cables from motors axes 3, 4, 5 and 6.

How to disconnect cables from motors is detailed in sections:

•






4 Repair


Continued

10

Action

Remove the bracket fitted on the tubular shaft unit.

Note

11

12

Remove the signal lamp , if used.

Remove the cable bracket on the armhouse.

xx0800000335

Parts:


• B: Attachment screws M6x16 quality 8.8-A2F (2 pcs)

• C: Bracket

13

14

Using caution, pull the cable package out of the hole where the cable bracket was fitted.

Stop the air from the Foundry Prime air hose. Insert a screw in the hose and a lock it with a hose clamp.

xx0800000338

Parts:

• A: Signal lamp

• B: Bracket






271

4 Repair


Continued

15

Action

Remove the attachment screws securing the upper arm to the lower arm.

Note

See the figure in:

•

Location of the complete upper arm on page 267

Note

Do not remove the attachment screws securing the gearbox axis 3 to the armhouse!

16 Remove the complete upper arm.

Attaching the lifting accessories to the upper arm

Attaching the lifting accessories

1

Action

Fit two screws in the wrist unit.

The purpose of these screws is to prevent the roundsling from sliding.

Note

Dimension is specified in


xx1100000568

2 Fit two rotating lifting points to the attachment holes in the arm house, see the figure. Secure the lifting point tightly against the arm house, but at the same time making sure that the screw does not bottom. Use an extra washer if the screw does bottom.




xx1100000565 xx1100000566





4 Repair


Continued

3

4

Action

Run a roundsling through each rotating lifting point and fasten both ends at the lifting hook.

Note



See figure

Attaching the roundslings to the upper arm on page 273

.

Make a loop of the third roundsling , running it around the wrist unit. Run the roundsling on both sides of the screws and fasten the free end of the roundsling to the lifting hook.



See figure

Attaching the roundslings to the upper arm on page 273

.

Attaching the roundslings to the upper arm

D

C

B

A xx1100000567

A

B

C

D

Screws to prevent the roundsling from sliding, 2 pcs

Rotating lifting point, 2 pcs

Roundsling around wrist unit

Length: 1.5 m.

Roundsling attached to arm house, 2 pcs

Length: 1.5 m.





273

4 Repair


Continued

Refitting the complete upper arm

Use this procedure to refit the complete upper arm.

Action Note

1

DANGER

Turn off all:



2 Clean the joints that have been opened. See


3

Note


4

CAUTION

The weight of the complete upper arm (including the wrist) is 140 kg


5

6

7

8

9

10

Clean all assembly surfaces.


See

Attaching the lifting accessories to the upper arm on page 272 .

Fit guide pins to the upper arm.

Specified in


.

Lift the upper arm to the robot using an overhead crane.

Release the brakes of the axis 3 motor.

Refit the upper arm to the lower arm with its attachment screws

Note

.

Use new attachment screws!

It may be necessary to turn the gear by rotating the motor pinion with a rotation tool, motor beneath the motor cover.

See the figure in:

•


Tightening torque :

• 35 Nm





4 Repair


Continued

11

Action

Using caution, push the cable package through the hole where the cable bracket will be fitted.

Note

12

13

14 xx0800000338

Parts:

• A: Signal lamp

• B: Bracket


Refit the air hose to the elbow fitting.

Refit the cable bracket with its attachment screws.

Reconnect all motor cables .

How to connect motor cables is detailed in sections:

•


15 Refit the bracket on the tubular shaft unit .

16

17

Refit the signal lamp , if used.



.

xx0800000335

Parts:



• C: Bracket





4 Repair


Continued

18

Action


19

DANGER



.

Note









4 Repair

4.4.2 Replacing complete tubular shaft unit

4.4.2 Replacing complete tubular shaft unit

Location of tubular shaft unit

The tubular shaft unit is located as shown in the figure.

xx0800000334

A

B

C

D

E

Armhouse

Parallel pin, hardened 8x16 m6 (2 pcs)

Attachment screws M8x35 quality 8.8-A2F and washers (10 + 10 pcs)

Tubular shaft unit

Wrist unit


Equipment

Tubular shaft unit

Guide pins

Cleaning agent

Sealing liquid

Standard toolkit


Note



2 pcs. Dimension: M8.

Isopropanol

Loctite 574








4 Repair


Continued


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001




1

Action Note










Axis Calibration in


.






Removing complete tubular shaft unit

Use this procedure to remove the complete tubular shaft unit.

1

2

Action


Drain oil from gearbox axis 4.

Note

How to drain the oil from the gearbox is described in section:

•






4 Repair


Continued

3

Action


Note

4

DANGER

Turn off all:



5

CAUTION


See


6 Remove the bracket securing the cable package to the tubular shaft unit by removing its attachment screws.

xx0800000336

7

8 xx0800000335

Parts:



• C: Bracket

Place the cable package in a way that it will not be damaged in the continued removal procedure.

Remove motors axes 4, 5 and 6.

How to remove motors is described in section:

•






279

4 Repair


Continued

9

Action

Tip

If only the tubular shaft unit shall be replaced, it is a good idea to remove the wrist unit at this stage.

Note

How to remove the wrist unit is detailed in section:

•

Removal of wrist unit on page 285

10

CAUTION

The robot arm tube weighs 65 kg.


11 Secure the tubular shaft unit with roundslings in an overhead crane.

CAUTION

Prevent the slings from sliding!

For example a small plate can be fitted to the lower attachment hole for the cable bracket (removed in a previous step). The plate should be fitted so it points downwards and functions as a mechanical stop for the roundsling.

At the other end of the tubular shaft unit, a shackle can be fitted if the wrist unit is removed.

12

13

Remove the attachment screws that secure the tubular shaft unit.

See the figure in:

•

Location of tubular shaft unit on page 277

Remove the tubular shaft unit using caution.

The tubular shaft unit is fitted with Loctite.

Note

CAUTION

Do not damage the gears when removing the tubular shaft unit.

There are two parallel pins guiding the tubular shaft unit into its place. See figure in

Replacing complete tubular shaft unit on page 277 .

CAUTION

Remaining oil will drain out from the gearbox cavity when the tubular shaft is lifted out.





4 Repair


Continued

Refitting complete tubular shaft unit

Use this procedure to refit the tubular shaft unit.

Action Note

1

DANGER

Turn off all:



2

3

4



Remove residues of old Loctite and other contaminations from the assembly surfaces.

Remove any painting from the assembly surfaces, with a knife.

Apply sealing liquid (Loctite 574) on the surface between the tubular shaft unit and the armhouse.

Make sure to apply the sealing liquid in circles around each of the attachment holes.

A

B

C

5

CAUTION

The robot arm tube weighs 65 kg.


D xx0800000457

Parts:

A Armhouse

B Surface where Loctite 574 shall be applied

C Tubular shaft unit

D Cylindrical pin (2 pcs)





281

4 Repair


Continued

6

Action

Secure the tubular shaft unit with a roundsling in an overhead crane.

Note

CAUTION

Prevent the slings from sliding!

For example a small plate can be fitted to the lower attachment hole for the cable bracket (removed in a previous step). The plate should be fitted so it points downwards and functions as a mechanical stop for the roundsling.

At the other end of the tubular shaft unit, a shackle can be fitted if the wrist unit is removed.

7

8

Fit guide pins in the upper arm house.

Specified in


.

Refit the tubular shaft unit, using caution.

Note

CAUTION

Do not damage the gears when refitting the tubular shaft unit.

There are two parallel pins guiding the tubular shaft unit into its place.

9

10

11

Secure the tubular shaft unit with its attachment screws .

See the figure in:

•

Location of tubular shaft unit on page 277


Refit motors axes 4, 5 and 6 .

How to refit motors is described in section:

•


Perform a leak-down test.

See

Performing a leak-down test on page 196

.

12 Refit the bracket securing the cable package to the tubular shaft unit, with its attachment screws .

xx0800000335

Parts:



• C: Bracket





4 Repair


Continued

13

14

15

Action Note

If the wrist unit has been removed from the tubular shaft unit, refit it now.

How to refit the wrist unit is detailed in section:

•

Refitting of wrist unit on page 286

Refill gearbox axis 4 with oil.

How to refill oil in gearbox is described in section:

•










.

17

DANGER



.




283

4 Repair

4.4.3 Replacing wrist unit

4.4.3 Replacing wrist unit

Location of wrist unit

The wrist unit is located in the upper arm as shown in the figures.

IRB 4600 -60/2.05

G

A

B

C

D

E

F xx0800000333

E

F

C

D

G

A

B

Upper arm

Gear

O-ring sealing plate

Wrist unit

Spring washer, conical 8.4x18x2, quality steel-mZn12c (7 pcs)

Attachment screw M8x40, quality steel 12.9 Gleitmo (7 pcs)

Guide pin

(only available for robots that are calibrated with Axis Calibration)


Equipment

Wrist unit

O-ring

Measuring tool

Standard toolkit

Note

For spare parts no. see Spare parts Upper arm (2.05/2.50/2.55) in Product manual, spare parts - IRB 2600 .

For spare parts no. see Spare parts Upper arm (2.05/2.50/2.55) in Product manual, spare parts - IRB 2600 .

For adjusting the play.







4 Repair


Continued

Equipment Note





Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001




1

Action




Note







Axis Calibration in


.






Removal of wrist unit

Use this procedure to remove the wrist unit.

1

Action


Note





4 Repair


Continued

Action Note

2

DANGER

Turn off all:



3 Drain oil from gearbox axes 5-6.

4

CAUTION

The robot wrist unit weighs 25 kg (IRB 4600 -

60/2.05, - 45/2.05, -40/2.55) and 15 kg (IRB 4600

- 20/2.50).


5 Secure the wrist unit with a roundsling in an overhead crane or similar.

6

CAUTION



How to drain the oil from gearbox axes

5-6 is described in section:

•


7 Remove the attachment screws and carefully remove the wrist unit.

See the figure in:

•

Location of wrist unit on page 284

CAUTION

Do not damage gears!

Refitting of wrist unit

Use this procedure to refit the wrist unit.

Action

1

DANGER

Turn off all:



Note







3

Action

Check if there is a parallel pin hole in the upper arm tube.

The hole is available on robots that are calibrated with the Axis Calibration method.

Note

4 Repair



4 If there is a hole, fit the parallel pin into the corresponding hole in the wrist (enclosed with the new wrist spare part).

Note

If the parallel pin is not installed on a robot calibrated with Axis Calibration, the calibration result will be affected negatively.

xx1600000689

Verify that the parallel pin sticks out from the wrist according to the measurement given below.

IRB 4600 -60/2.05

6 ±0,5

5 Clean all assembly surfaces.


xx1600000702





287

4 Repair


Continued

6

7

Action Note

Check the o-ring . Replace if damaged.

Prepare the refitting of the wrist by inserting the attachment screws and washers in the upper arm tube.

See the figure in:

•


8

CAUTION

The robot wrist unit weighs 25 kg (IRB 4600 -

60/2.05, - 45/2.05, -40/2.55) and 15 kg (IRB 4600

- 20/2.50).


9 Carefully put the wrist unit in its place on the upper arm .

CAUTION

Do not damage gears!

CAUTION

Make sure that the o-ring stays in place on the wrist unit!

10 Adjust the play of the wrist by following these steps:

• Fit the measuring tool at the rear of the motor.

• Push the wrist as shown in the figure to locate the smallest play in the same way as for adjustment of motors for axes 4,

5 and 6. See

Refitting motors on page 314 .

11

12

13 xx1000000223

Parts:

• A: Gears on drive shaft unit, axes 5-6

• B: Gears on the wrist

Secure the wrist unit with its attachment screws and washers .

See the figure in

•



Measure the play by moving axes 5 and 6 with the measuring tool.

How to measure the play is described in sections:

•

Measuring the play, axis 5 on page 290

•

Measuring the play, axis 6 on page 292


See

Performing a leak-down test on page 196 .





4 Repair


Continued

14

Action

Refill oil in gearbox axes 5-6.

Note

How to fill oil in gearbox axes 5-6 is described in section:

•






.

16 Recalibrate the robot.

Pendulum Calibration is described in

Operating manual - Calibration Pendulum , enclosed with the calibration tools.





17

DANGER






289

4 Repair

4.4.4 Measuring the play, axis 5

4.4.4 Measuring the play, axis 5

General

After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed below.


Equipment, etc.

Standard toolkit -




Measuring tool, play

(IRB 4600 -60/2.05



3HAB1611-6



Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Article number

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001

Measurement, axis 5

The procedure below details how to measure the play of axis 5.

Note

1

The measuring tool and measuring values differ depending on robot version.


2

3

DANGER

Turn off all:



Move the robot to calibration position and turn the axis 4 90°.

Fit the measuring tool, play to the turning disc.







4 Repair


Continued

4

Action

Apply load F in one direction, as shown in the figure to the right.

Note

Information

Different load and distances for the different robot versions, as specified to the right!

5

6

Remove the load and set the dial indicator to zero.

Apply load F in the opposite direction, as shown in the figure to the right.

xx0300000186

Values for IRB 4600 - 60/2.05

• A: Measuring tool, play

• B: 207.5 mm

• C: 135 mm

• F: 90N

7 xx0300000187

Values for IRB 4600 -60/2.05


• B: 207.5 mm

• C: 135 mm

• F: 90N

Remove the load and measure the play by reading the dial indicator.

The maximum play allowed at the given distance from the center of axis 5 is, for robot version:

• IRB 4600 -60/2.05




291

4 Repair


4.4.5 Measuring the play, axis 6

General

After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed below.


Equipment

Standard toolkit -





(IRB 4600 -60/2.05



3HAB1611-6



Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Article number

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001

Measurement, axis 6

The procedure below details how to measure the play in axis 6.

Note

1

The measuring tool and measuring values differ depending on robot version.


2

DANGER

Turn off all:



Fit the measuring tool, play to the turning disc.







4 Repair


Continued

3

Action

Attach a weight (m) at a distance (B) from the wrist flange, in order to avoid the effects of play on axis 5.

Note

Information

Different weight and distance for the different robot versions, as specified to the right.

4 Apply load F in one direction.

Note

Different load and distances for the different robot versions, as specified to the right.

xx0300000188

Values for robot versions IRB 4600 -60/2.05


• B: 207.5 mm

• m: 20 kg

5

6

Remove the load and set the dial indicator to zero.

Apply load F in the opposite direction, as shown in the figure to the right.

xx0300000189



• B: 100 mm

• C: 100 mm

• F: 50N xx0300000190



• B: 100 mm

• C: 100 mm

• F: 50N





4 Repair


Continued

7


Remove the load and measure the play by reading the dial indicator.

The maximum play allowed at the given distance (B) from the center of axis 6 is, for robot version:

• IRB 4600 -60/2.05




4.5 Lower arm

4.5.1 Replacing the lower arm

Location of lower arm

The lower arm is located as shown in the figure.

4 Repair

4.5.1 Replacing the lower arm

B

C

D E

A

F

G

H

J xx0800000360

D

E

F

A

B

C

G

H

J

Upper arm

Axis-3 gearbox

Lower arm

Washer (19 pcs)

Attachment screws M8x40 quality Steel 12.9 Gleitmo (19 pcs)

Frame

Axis-2 gearbox

Washer (18 pcs)






4 Repair


Continued


Equipment

Lower arm

Lifting eye

Standard toolkit

Note

For spare parts no. see Spare parts Lower arm and motors in Product manual, spare parts - IRB 2600 .

Valid for Other design than Type C:

M8


M10



.




Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001




1

Action Note










Axis Calibration in


.







Action




Note

Removing the lower arm

Use this procedure to remove the lower arm.

1

2

Action



Note

4 Repair



3

DANGER

Turn off all:



4

5

Remove the cable package from all axes except in the base.

How to remove the cable package in frame, lower arm and armhouse is described in sections:

•


•


•

Replacement of air nipples and hoses (Foundry Prime) on page 233

Secure the upper arm with a roundsling in an overhead crane.

6

CAUTION


See






4 Repair


Continued

7

Action Note

Remove the complete upper arm and put it on a loading pallet.

How to remove the complete upper arm is described in section:

•

Removing the complete upper arm on page 269

8

CAUTION

The robot lower arm weighs 65 kg.


9 Fit a lifting lug in one of the upper holes in the lower arm, for the attachment screws.

10 Remove the attachment screws and washers that secure the lower arm to the axis-2 gearbox.

xx0800000379

Parts:

• A: Lifting lug xx1800000935

11 Remove the lower arm.





Refitting the lower arm

Use this procedure to refit the lower arm.

Action

1

DANGER

Turn off all:





3

CAUTION

The robot lower arm weighs 65 kg.


4 Fit a lifting lug in one of the upper holes in the lower arm, for the attachment screws.

Note

4 Repair


Continued

5 Secure the lower arm with a roundsling in an overhead crane and lift it to the robot.

xx0800000379

Parts:

• A: Lifting lug





299

4 Repair


Continued

6

Action Note

Refit the attachment screws and washers to secure the lower arm to the axis-2 gearbox.

Attachment screws: M12x50 quality steel

Gleitmo 12.9 (18 pcs)


300 xx1800000935

7

8

9

Secure the complete upper arm with roundslings in an overhead crane and lift it to the robot.

Refit the complete upper arm .

How to refit the complete upper arm is described in section:

•

Refitting the complete upper arm on page 274

Refit the cable package .

How to refit the cable package in frame, lower arm and armhouse is described in sections:

•


•


•

Replacement of air nipples and hoses (Foundry Prime) on page 233

10

11



.







.

12

DANGER



.




4 Repair

4.6.1 Replacing stop pin axis 1

4.6 Frame and base

4.6.1 Replacing stop pin axis 1

Location of stop pin axis 1

The stop pin axis 1 is located as shown in the figure.

xx0800000045

A

B

C

D

E

Attachment screws M6x16 quality 8.8-A2F (2 pcs)

Bracket

O-ring (2 pcs) - Not used if bracket (D) is installed.

Bracket

Stop pin


Equipment

Stop pin

Standard toolkit

Note

For spare parts number, see Spare parts -

Frame and base in Product manual, spare parts - IRB 2600 .



.





4 Repair


Continued

Equipment Note




Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

Removing the stop pin, axis 1

Use this procedure to remove the stop pin axis 1.

Action Note

1

DANGER

Turn off all:



2

CAUTION


See


3

4

Remove the attachment screws securing the bracket and stop pin .

Remove the bracket and stop pin .

See the figure in

•

Location of stop pin axis 1 on page 301

See the figure in

•






4 Repair


Continued

Refitting the stop pin, axis 1

Use this procedure to refit the stop pin axis 1.

Action Note

1

DANGER

Turn off all:



2

3



Fit the two o-rings on the stop pin.

Note

See the figure in

•


The o-rings are not used when bracket (D) is installed.

4 Fit the stop pin on the bracket .

Note

The small spike on the bracket shall be pointing downwards for correct fitting of the stop pin.

A

C

5

6

B xx0800000453

Parts:

• A: Bracket

• B: Stop pin

• C: Small spike

Secure the stop pin together with bracket

(D) on the frame with its attachment screws .

Use Locking liquid

3HAB7116-1 (Loctite 243).


See the figure in

•




.





4 Repair


Continued

Action

7

DANGER



.

Note




4 Repair

4.7.1 Removing motors

4.7 Motors

4.7.1 Removing motors

Introduction

This procedure describes how to remove motors on all axes of the robot.

Location of axis-1 and axis-2 motors (Foundry Prime)

The figure shows axis-1 motor on IRB 4600 Foundry Prime.

xx1100000083

F

G

D

E

A

B

C

Attachment screws M5x16, quality Steel 8-A2F (7 pcs)

Motor cover

Attachment screws, motor axis 1 (4 pcs) + washers

Tightening torques and attachment screws on page 318

.

Connection box

Axis-1 motor

O-ring

Cable gland cover





4 Repair


Continued

I

H Hose protection

Elbow nipple

Location of axis-3, axis-4, axis-5 and axis-6 motors

The axis-3, axis-4, axis-5 and axis-6 motors are located as shown in the figures.

Motors: (3) = Axis-3 motor. (4) = Axis-4, axis-5 and axis-6 motors.

F

G

H

C

D

E xx0900000303

A

B

B

Markings inside armhouse, identifying the position of each motor

Attachment screws, axis-3 motor (4 pcs) + washers. See


Attachment screws, axis-4, axis-5 and axis-6 motors (3x4 pcs) + washers.


Axis-3 motor

Axis-4 motor

Axis-5 motor

Axis-6 motor

O-ring (axis-4, axis-5 and axis-6)

Armhouse





Connectors, axis-3 and axis-4 motors

The figure shows the connectors of motors axes 3-6.

4 Repair


Continued

MP5

FB5

FB4

MP4

MP3

FB3

FB6

MP6 xx0900000410


Equipment

Standard toolkit

Note







Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol

CAUTION



.





4 Repair


Continued

Weights

The motors for the different axes weighs according to the table:

Motor

Axis-1 motor

Axis-2 motor

Axis-3 motor

Axis-4 motor

Axis-5 motor

Axis-6 motor

Weight in kg

13 kg

25 kg

13 kg

8 kg

8 kg

8 kg

CAUTION

All lifting equipment must be sized accordingly!




1

Action




Note







Axis Calibration in


.










4 Repair


Continued

Position of robot

Use this procedure to place the robot in the position recommended in order to facilitate replacement of motors.

Action

Axis-1, axis-4, axis-5 and axis-6 motor

• Move the robot to a position where the wrist is pointing to the floor, as shown in the figure. This will make it possible to remove the motors without draining the oil from the gearbox.

Information

Axis-2 motor

• Move the robot to a position where the lower arm rests firmly on the damper of axes 2 and 3. Release the brake of axis

2 to be sure that the lower arm rests in the end position.

xx0800000388

Axis-3 motor

• Move axis-2 to 0° and axis-3 to maximal

+. Release the brake of axis-3 to be sure that the upper arm is completely vertical and rests against the damper of axis-2 and axis-3.

xx1100000548

Draining gearbox

Use this procedure to drain gearboxes, if needed.

Note

Draining of gearbox is only needed when removing the axes 2 and 3 motors.

1

2

Action

Axis-1 motor:

• Draining of gearbox is not needed.

Axis-2 motor:

• The gearbox has to be drained before removing the motor.

-

Note

How to drain the gearbox is described in section:

•






4 Repair


Continued

3

4

Action

Axis-3 motor:

• The gearbox has to be drained before removing the motor.

Axis-4, axis-5 and axis-6 motors:

• Draining of gearbox oil is not needed if robot is positioned as recommended.

-

Note


•


Removing motors

Use this procedure to remove the axis-1, axis-2, axis-3, axis-4, axis-5 and axis-6 motors.

Note

The procedure contains information how to remove motors on all axes of the robot. Some steps are only applicable to a certain motor. Follow the steps carefully in order not to miss vital information!

1

2

Action


Note

Move the robot to the recommended position for the motor that shall be removed.

See


.

•

Position of robot on page 309

3

DANGER

Turn off all:



4 Check if the gearbox needs to be drained.

See


.

•

Draining gearbox on page 309

5

CAUTION







4 Repair


Continued

6

Action

Only applicable to axis-3, axis-4, axis-5 and axis-6 motors!

Remove the cover in the back of the arm house.

Note

B

WARNING

The robot must never be run without the cover in the armhouse fitted! It is a vital supporting part of the robot.

7

8

9

A xx0800000389

Parts:

• A: Cover

• B: Attachment screws (10 pcs)

+ washers.

Only applicable to axis-1 and axis-2 motors!

Remove the motor cover.

See the figure in:

•

Location of axis-1 and axis-2 motors (Foundry Prime) on page 305


Remove the cable gland cover.

See the figure in:

•



Remove the connection box.

Note

See the figure in:

•


Only needed if the motor shall be replaced with a new one.

10 Disconnect the motor cables .

Note

When removing the axis-3 motor, the cables of the axis-4, axis-5 and axis-6 motors must be disconnected too. This must be done in order to be able to remove the bracket on top of the axis-

3 motor.





311

4 Repair


Continued

11

Action

Only applicable to axis-3 motor!

Remove the bracket from the axis-3 motor.

Note

12 xx0800000390

Parts:

• A: Axis-3 motor

• B: Bracket

In order to release the brakes of the motor to be removed, connect the 24 VDC power supply to the motor.

Only applicable to motors axes 2 and 3!

Release the brake of axis 2 untill the lower arm firmly rests on the damper.

Connectors:

• Axis-1 motor: R2.MP1






Connect to pins:

• + : pin 2

• -: pin 5

CAUTION

The connections for the motor brakes

(24 VDC connection) are phase dependent. If the connection on the pins is switched, it can cause severe damage to vital parts.

13

Note

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!

14

15

Remove the attachment screws securing the motor.

If needed use a 300 mm extension for bits 1/2"

(Motor axis 1).

See the figure in:

•


If required, press the motor out of position by fitting two screws in the threaded holes in the motor flange.

Note

Always use removal tools in pairs diagonal to each other.





4 Repair


Continued

16

Action

Remove the motor!

Note

CAUTION

Lift the motor gently in order not to damage pinion or gears.

17

18

Only applicable to motor axis 1!

Cover the hole if replacement of motor axis 1 is not immediate, in order to avoid contamination.

See the figure in:

•


Only applicable to motors axes 4, 5 and 6!

Check that the o-ring also is removed. It might stay in the armhouse when the motor is removed.

See the figure in:

•





313

4 Repair

4.7.2 Refitting motors

4.7.2 Refitting motors

Introduction

This procedure describes how to refit motors on all axes of the robot.

WARNING

When a motor is replaced, make sure to use the correct type of new motor. Motors of different types may not be compatible. See the Spare parts manual on myABB business portal ( www.myportal.abb.com

).

Location of axis-1 and axis-2 motors, (Foundry Prime)

The figure shows motor axis1 on IRB 4600 Foundry Prime.

D


314 xx1100000083

A

B

C

Attachment screws M5x16, quality Steel 8-A2F (7 pcs)

Motor cover

Attachment screws, motor axis 1 (4 pcs) + washers


.

Connection box




4 Repair


Continued

E

F

G

I

H

Motor, axis 1

O-ring

Cable gland cover

Hose protection

Elbow nipple

Location of axis-3, axis-4, axis-5 and axis-6 motors

The axis-3, axis-4, axis-5 and axis-6 motors are located as shown in the figures.

Motors:

(3) = Axis-3 motor

(4) = Axis-4, axis-5 and axis-6 motors

G

H

E

F

C

D xx0900000303

A

B

B

Markings inside armhouse, identifying the position of each motor

Attachment screws, axis-3 motor, (4 pcs) + washers. See


Attachment screws, axis-4, axis-5 and axis-6 motors, (3x4 pcs) + washers. See


Axis-3 motor

Axis-4 motor

Axis-5 motor

Axis-6 motor

O-ring (axis-4, axis-5 and axis-6)

Armhouse





315

4 Repair


Continued

Connectors, axis-3 and axis-4 motors

The figure shows the connectors of the axis-3 and axis-4 motors.

MP5

FB5

FB4

MP4

MP3

FB3

FB6

MP6 xx0900000410


Equipment

Standard toolkit

Note






Lifting tool, axis-2 For art. no. see Reference information .

Lifting tool, axis-3

Motors

For art. no. see Reference information .

For spare part no. see


.


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol





4 Repair


Continued

CAUTION



.

Weights

The motors for the different axes weighs according to the table:

Motor

Axis-1 motor

Axis-2 motor

Axis-3 motor

Axis-4 motor

Axis-5 motor

Axis-6 motor

Weight in kg

13 kg

25 kg

13 kg

8 kg

8 kg

8 kg

CAUTION

All lifting equipment must be sized accordingly!

Position of robot

Use this procedure to place the robot in the position recommended in order to facilitate replacement of motors.

Action

Axis-1, axis-4, axis-5 and axis-6 motors

• Move the robot to a position where the wrist is pointing to the floor, as shown in the figure. This will make it possible to remove the motors without draining the oil from the gearbox.

Information

Axis-2 motor

• Move the robot to a position where the lower arm rests firmly on the axis-3 damper. Release the axis-2 brake to be sure that the lower arm rests in the end position.

xx0800000388




xx1100000548


317

4 Repair


Continued

Action

Axis-3 motor

• Move axis-2 to 0° and axis-3 to maximal

+. Release the axis-3 brake to be sure that the upper arm is completely vertical and rests against the damper.

Information

Filling oil in gearbox

Use this procedure to fill oil in gearbox, if needed.

Note

Filling oil in the gearbox is only needed when refitting motors axes 2 and 3.

1

2

Action

Axis-1 motor:

• Filling gearbox oil not needed.

Axis-2 motor:

• Refill oil in gearbox after refitting.

-

Note

3 Axis-3 motor:

• Refill oil in gearbox after refitting.

4 Axis-4, axis-5 and axis-6 motors:

• Filling gearbox oil not needed.

-

How to fill oil in gearbox is described in section:

•


How to fill oil in gearbox is described in section:

•


Tightening torques and attachment screws

The table shows the tightening torques for all motors.

Motor

Motor, axis 1

Motor, axis 2

Motor, axis 3

Motor, axis 4

Motor, axis 5

Motor, axis 6

Attachment screw

M8x25

Quality

8.8-A2F

Screwlengths depending on flange thickness on page 318

8.8-A2F

Screwlengths depending on flange thickness on page 318

8.8-A2F

M8x25

M8x25

M8x25

8.8-A2F

8.8-A2F

8.8-A2F

Tightening torque

22 Nm

35 Nm

22 Nm

22 Nm

22 Nm

22 Nm

Screwlengths depending on flange thickness

Screwlengths can vary depending on when the robot is delivered. The different screwlengths depends on the different flange thickness of motors. Make sure to use the correct screwlength! See table:

Motor axis 2

Flange thickness

18.5 mm


318

Attachment screws

M10x40

Motor axis 3

Flange thickness

15 mm

Attachment screws

M8x35




Motor axis 2

16 mm M10x35

4 Repair


Continued

Motor axis 3

13 mm M8x30 xx0900000443

A Flange thickness

Preparations before the refitting of motors

Use this procedure to make necessary preparations before refitting motors.

Action Note

1

DANGER

2

3

4

5

6

Turn off all:



Grind the paint on the surface carefully to get a smoth surface.

Clean the surface from contamination such as oil and dirt.


Make sure that the motor and the pinion are not damaged or scratched.

Lightly lubricate the o-ring with grease .

Make sure the o-ring on the flange of the motor is seated properly.

xx0900000082

Parts:

• A: Correct position of o-ring

• B: Incorrect position of o-ring !

Replace with a new o-ring if damaged!





319

4 Repair


Continued

7

Action Note

In order to release the brakes, connect the 24

VDC power supply.

Connectors:

• Motor axis 1: R2.MP1






Connect to pins:

• + : pin 2

• -: pin 5

CAUTION

The connections for the motor brakes

(24 VDC connection) are phase dependent. If the connection on the pins is switched, it can cause severe damage to vital parts.

Refitting motors

Use this procedure to refit motors axes 1, 2, 3, 4, 5 and 6.

Note

The procedure contains information how to refit motors on all axes of the robot.

Some steps are only applicable to a certain motor. Follow the steps carefully in order not to miss vital information!

1

Action

Note

Before starting the refitting of the motor, first make the necessary preparations!

Information

See


•

Preparations before the refitting of motors on page 319

2

Note








4

Action

Apply Loctite 574 on the surface as shown (A) in the figure.

Information

4 Repair



5

6

7

Place the motor carefully in the gearbox.

Fit the motor, making sure the motor pinion is properly mated to the gear in the gearbox.

Make sure that:

• the motor is turned the correct way

• the pinion or gear of the motor does not get damaged!

Applicable to motor axis 3!

Make sure that the wire exit holes of motor axis

3 are in the correct position. See illustration!

A xx0900000300

Parts:

• A: Wire exit holes, motor axis 3





321

4 Repair


Continued

8

Action

Applicable to motors axes 4, 5 and 6!

Make sure that the wire exit hole of the motor is in the correct position.

Information

9

10

11 xx0900000062

Parts:

• A: Wire exit hole, motor axis 4

• B: Wire exit hole, motor axis 5

• C: Wire exit hole, motor axis 6


Fit the attachment screws for the motor and fasten them sligthly. The motor must be able to move parallel to the gear during the adjustment of the play.


Adjust the play of the motor.

See

Adjusting the play of axis 4, 5 and

6 motors on page 325

.

Secure the motor with its attachment screws and washers .

Note

Tightening torque and attachment screws are specified in the table:

•


Apply the correct tightening torque!

12

13

Disconnect the brake release voltage.

Only applicable to motors axes 1 and 2!

Refit the connection box (if it has been removed).

See the figure in:

•

Location of axis-1 and axis-2 motors, (Foundry Prime) on page 314

Note

Make sure that the o-ring is in place!





14

Action

Applicable to motor axis 3!

Refit the bracket on motor axis 3.

Information

4 Repair



Parts:

• A: Motor axis 3

• B: Bracket

15

16

Reconnect the motor cables.

Applicable to motor axes 1 and 2!

Refit the cable gland

Make sure that the and o-ring motor covers is in place!

.

See the figure in:

•

Location of axis-1 and axis-2 motors, (Foundry Prime) on page 314

Note

Make sure that the cover is tightly sealed!

17

18

Applicable to motors axis 2!

Refill gearbox oil.

How to fill oil in the gearbox is described in sections:

•


•


Applicable to motors axes 3, 4, 5 and 6!

Make sure that the gasket on the cover on the armhouse is intact.

If the gasket is damaged, it need to be replaced.





323

4 Repair


Continued

19

Action

Applicable to motors axes 3, 4, 5 and 6!

Refit the cover in the back of the armhouse with its attachment screws and washers.

WARNING


B

Information

Make sure that the cover is tightly sealed.

A xx0800000389

Parts:

• A: Cover

• B: Attachment screws M6x25, quality 8.8-A2F (10 pcs)

Tightening torque:

• 14 Nm

20

21

Make sure that the armhouse cover is tightly fitted. If there is a gap between the cover and the robot, seal with Sikaflex 521 FC.


See


.

22 Recalibrate the robot.

Pendulum Calibration is described in

Operating manual - Calibration Pendulum , enclosed with the calibration tools.


Calibrating with Axis Calibration method on page 364

.



.

23

DANGER






4 Repair

4.7.3 Adjusting the play of axis 4, 5 and 6 motors

4.7.3 Adjusting the play of axis 4, 5 and 6 motors


Equipment

Measuring tool

Standard toolkit

Note

For adjusting the play.






Adjusting the play of axis 4, 5 and 6 motors

1

2

3

Action

Fit the measuring tool at the rear of the motor.

Adjust the play on the motor by starting with a big play and then gradually finding the smallest play. Use swift movements in order to avoid noticing the magnetic field which causes the gears to stick together. Follow the instructions for current motor:

Motor axis 4:

1 Turn the motor shaft six turns and find the smallest play within this range.

Axis 5 motor:

1 Turn the outgoing shaft for axis 4 in intervals of 90° for one full turn and find the smallest play for the axis 5 motor within this range.

2 Turn the axis 5 motor one full turn at a time for a total of five turns and find the smallest play within this range.

Axis 6 motor:

1 Turn the outgoing shaft for axis 4 in intervals of 90° for one full turn and find the smallest play for the axis 6 motor within this area.

2 Turn the axis 5 motor one full turn at a time for a total of five turns and find the smallest play for axis 6 within this range.

3 Turn the axis 6 motor one full turn at a time for a total of three turns and find the smallest play for axis 6 within this range.

Push or tap the motor in radial direction so that the play becomes minimal within one motor turn, without the gear "chewing".

Note




325

4 Repair

4.8.1 Replacing gearbox axis 1

4.8 Gearboxes

4.8.1 Replacing gearbox axis 1

Location of gearbox

The gearbox is located as shown in the figure. The exploded view only shows the principle of the assembly. The actual replacing is recommended to be done with the robot resting on its side.

xx1100000007

E

F

C

D

A

B

G

H

Frame

Radial sealing

O-ring

Gearbox axis 1

Washer (21 pcs)


Radial sealing

Sealing ring





4 Repair


Continued

I

J

K

L

M

Washer

Attachment screws

O-ring

Attachment screws

Cover


Equipment

Gearbox

Guide pins

Guide for reduction gear

Standard toolkit

Note

See



Used to guide the gearbox during removal/refitting.


3HACxxx

Used to guide axis-1 gear and frame during refitting.






Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001




1

Action




Note





327

4 Repair


Continued

Action Note







Axis Calibration in


.






Illustration of robot put down on its side

The robot is put down on its side for a safe removal of the axis-1 gearbox. Prepare an area on the floor with cardboard, plastic foam or similar and prepare higher support for the wrist.

Make sure the cabling brackets on the lower arm are unfastened and moved out of the way so that the cabling is not getting squeezed.

xx1800000593

Removing gearbox axis 1

Use this procedure to remove the gearbox.

1

2

Action Note


Drain the oil from the gearbox.

How to drain the oil from the gearbox is described in section:

•






4 Repair


Continued

3

Action

Jog the robot to:

• Axis 1: 0 °

• Axis 2: 0°

• Axis 3: -10°

• Axis 4: 0°

• Axis 5: 0°

• Axis 6: 0°

4

DANGER

Turn off all:



5

CAUTION


See


Note

6

7

Remove the axis-1 motor.

See

Removing motors on page 305 .

Remove the complete arm system from the base and lay down the robot on its side.

See

Removing the base on page 259

.

xx1800000593





329

4 Repair


Continued

8

Action

Fit a lifting lug in the uppermost hole for the base attachment screws.

Note xx0800000440

A Roundsling

B Lifting lug

C Uppermost base attachment hole

D Axis-1 gearbox

9

CAUTION

The gearbox weighs 27 kg.


10

11

Secure the gearbox in an overhead crane or similar.

Remove the attachment screws securing the gearbox.

See the figure in:

•

Location of gearbox on page 326

12 Remove two gearbox attachment screws opposite to each other and fit two guide pins into the holes.

xx1800000789


Always use guide pins in pairs!





13

Action

Remove the remaining attachment screws and washers.

Note

4 Repair



14

Note


15

Note

There will be some excess oil running out of the gearbox when it is removed. Use some absorbent material to catch the oil.

16 Slide the gearbox out onto the guide pins and lift it away.

If necessary use removal tools to remove the gearbox.

Note


xx1800000791





331

4 Repair


Continued

Refitting gearbox axis 1

Use these procedures to refit the gearbox.

Refitting the gearbox to the frame

Action

1

DANGER

Note

2

3

Turn off all:





Check the radial sealing in the frame.

Replace if damaged.

4 Fit a lifting lug in the uppermost hole for the base attachment screws.

xx1800000794


332 xx0800000440

A Roundsling

B Lifting lug

C Uppermost base attachment hole

D Axis-1 gearbox




Action

5

Note

Check, when fitting the lifting lug, that both oil plugs will be placed in the correct position after the gearbox is fitted as shown in the figure. The oil plugs shall be placed in the openings in the frame.

Note

4 Repair


Continued

A

B

6 Apply grease on the o-ring .

7

8



Fit two guide pins to the frame.

xx0800000441

A Opening for oil plug in frame

B Oil plug

See the figure in:

•

Location of gearbox on page 326

Replace o-ring if damaged.

9 xx1800000793



Fit the guide for the gear on top of the protection tube.

It protects the radial sealing from being damaged during refitting.

Guide for reduction gear: 3HACxxx.

xx1800000795





333

4 Repair


Continued

Action

10

CAUTION



Note

11 Lift the gearbox onto the guide pins and slide it into position, using caution.

Check that the radial sealing in the frame tube does not get damaged.

Double check that the oil plugs are in the correct position.

12

13 xx0800000441

A Opening for oil plug in frame

B Oil plug

Secure the gearbox with its attachment screws and washers.

Remove the guide pins from the frame and secure the remaining two screws.

A xx1800000791

B xx1800000790

• 35 Nm





14

Action

Remove the guide from the protection tube.

Note

4 Repair



Refitting the arm system to the base

1

2

3

4

5

6

Action Note

Refit the complete arm system to the base.

See

Refitting the base on page 263 .

Refit the axis-1 motor.

Refit the cable harness in the base, the frame and the lower arm.

Refill oil in the gearbox.

See


.

See

Replacing gearbox axis 1 on page 326 .

•


•


•


See

Changing the oil, axis 1 gearbox on floor mounted robots on page 153 .



.







7

DANGER



.




335

4 Repair



Location of gearbox axis 2

The gearbox is located as shown in the figure.

xx1100000006

A

B

D

E

F

G


Washers (15 pcs)

Sleeve (delivered with gearbox)

Gearbox axis 2

O-ring

Frame





4 Repair


Continued


Equipment

Gearbox

Rotation tool

Lifting accessories

Guide pin, M12x150

Standard toolkit


Article number

See


.

Note

3HAB7887-1

-

3HAC13056-2

Roundslings.




.



Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001




1

Action




Note







Axis Calibration in


.







4 Repair


Continued

Action




Note



WARNING

The procedure details how to replace the gearbox without removing the cable harness, only by loosening it. This means that the upper and lower arm will be separated from the frame but still be connected to the frame through the cabling.

Be careful not to damage the cables!

1

2

Action


Note


Upper arm should rest on the axis-3 damper.

The figure shows IRB 2600 but the position of the robot is correct.

xx1200000068





4 Repair


Continued

Action Note

3

DANGER

Turn off all:



4 Drain the gearbox.


•


5

CAUTION



.

6 Loosen the cabling from the lower arm by removing two cable brackets and a cable strap.

B

C

A

7

CAUTION

The weight of the complete upper and lower arm together is 205 kg


8 Attach a roundsling around the upper arm house.

xx1100000946

A Cable bracket

B Cable bracket

C Cable strap





339

4 Repair


Continued

9

Action

Unload the weight of the lower and upper arm package by stretching the roundslings with the overhead crane.

Turn on the power temporarily and release the brakes of axis 2 to rest the weight onto the roundslings.

Note

10

DANGER

Turn off all:



11 Remove the attachment screws and washers that secure the lower arm to the axis-2 gearbox.

12 Remove the lower and upper arm package from the frame.

WARNING

The cable harness is still installed on the robot! Make sure not to damage the cables or the cable brackets on the robot.

13

CAUTION

The gearbox weighs 51 kg


xx1800000935





14

Action

Fit a lifting lug in the uppermost hole for the attachment screws that secure the lower arm to the gearbox.

Note

A

4 Repair


Continued

B

C

15

16

17

18 xx0800000445

Parts:

• A: Gearbox axis 2

• B: Lifting lug

• C: Holes for attachment screws that secure the lower arm to the axis-2 gearbox

Secure the gearbox with a roundsling in an overhead crane or similar.

Remove the attachment screws and washers that secure the gearbox to the frame.

See the figure in:

•

Location of gearbox axis 2 on page 336

Fit guide pins to help guiding the gearbox out from the frame.



If necessary, use removal tools to remove the gearbox.

Note


19 Remove the gearbox.

CAUTION

Use caution in order not to damage gearbox or pinion!

Refitting gearbox axis 2

Use this procedure to refit the gearbox.

Action

1

DANGER

Turn off all:



Note





4 Repair


Continued

Action

2

CAUTION


See


3

CAUTION

The gearbox weighs 51 kg


4 Fit a lifting lug in the uppermost hole for the attachment screws securing the lower arm to the gearbox.

Note

A

B

C

5

6

7

8

9 xx0800000445

Parts:

• A: Gearbox axis 2

• B: Lifting lug

• C: Holes for attachment screws securing the lower arm to gearbox axis 2.



Apply some grease on the o-ring before fitting.


Replace if damaged.

O-ring, nitrile rubber: 3HAB3772-120.

See the figure in:

•


Fit two guide pins in opposite holes in the frame.



Secure the gearbox with a roundsling in an overhead crane or similar.






4 Repair


Continued

10

Action Note

Lift the gearbox onto the guide pins and slide it into position while rotating the motor pinion to find the mating position. Use a rotation tool .



.

Note

The position of the oil plug shall be according to the illustration.

11

12

Secure the gearbox with its attachment screws and washers .


13

14

Fit the guide pins to the gearbox.

CAUTION

The weight of the complete upper and lower arm together is 205 kg


xx1000000307

Parts:

• A: Position of oil plug on gearbox

See screw dimension in the figure in:

•



See


.

15

16

Lift the upper and lower arms into mounting position and guide them in place with the guide pins.

It might be necessary to rotate the motor pinion with the rotating tool to find the mating position.

Refit the attachment screws and washers to secure the lower arm to the axis-2 gearbox.

Attachment screws: M12x50 quality steel

Gleitmo 12.9 (18 pcs)


xx1800000935





343

4 Repair


Continued

17

Action

Refit the cable brackets and cable strap to the lower arm.

Note

C

B

A


xx1100000946

A Cable bracket

B Cable bracket

C Cable strap

How to fill the gearbox with oil is described in section:

•


19

20



.







21

DANGER



.





Location of gearbox axis 3

The gearbox is located as shown in the figure.

A

4 Repair


B

C

D

E xx0800000398

C

D

E

A

B

Upper arm

O-ring

Axis-3 gearbox

Washers (18 pcs)



Equipment

Gearbox

Guide pins

Art. no.

Note

See


.

M8 (2 pcs)

Used to guide the gearbox and the upper arm during removal/refitting.

Rotation tool 3HAB7887-1





4 Repair


Continued

Equipment

Standard toolkit


Art. no.

Note



.



Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush


Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

3HAC035355-001




1

Action




Note







Axis Calibration in


.










4 Repair


Continued



WARNING

The procedure details how to replace the gearbox without removing the cable harness. This means that the upper and lower arm will be separated but still be connected to eachother through the cabling. Be careful not to damage the cables!

1

2

3

Action


Drain the gearbox.

Note


•



4

DANGER

Turn off all:



5

CAUTION


See


xx0800000336





347

4 Repair


Continued

6

Action

Unscrew the attachment screws securing the cable harness to the lower arm by the the two cable brackets and a cable strap.

Note

C

B

A xx1100000946

A Cable bracket

B Cable bracket

C Cable strap

7 Loosen the cabling from the lower arm by unhooking the two cable brackets.

CAUTION

The cable harness is still mounted in other parts of the robot. Make sure not to damage the cable harness or any cable brackets in the continued removal.

8

9

10

11


See

Attaching the lifting accessories to the upper arm on page 272

Connect the 24 VDC power supply to the axis-3 motor and release the brakes.

Releasing the brakes of the axis-3 motor unloads the weight of the upper arm by stretching the roundslings.

Remove the attachment screws that secure the upper arm to the lower arm.

See the figure in:

•


Note


12

CAUTION

The robot upper arm weighs 140 kg.






4 Repair


Continued

13

Action

Remove the upper arm from the lower arm and leave it hanging in the air.

Note

WARNING

CAUTION

When the upper arm no longer is attached to the robot, the armhouse has a tendency to drop down a little. In order to prevent this is to rise the front end of the upper arm a little before removing the attachment screws securing the upper arm.

The cable harness is still installed on the robot! Make sure not to damage the cable harness or the cable brackets on the robot.

14

CAUTION



15 Remove two attachment screws diagonally located and insert guide pins.


16 Remove the remaining attachment screws that secures the gearbox.

See the figure in:

•


17

Note

There will be some surplus oil in the gearbox. Place some absorbant cloth or similar under the gearbox.

18 Slide the gearbox carefully out onto the guide pins and lift it away.

If necessary, use a pair of screws to push out the gearbox.

Note


CAUTION

Remaining oil will drain out from the gearbox cavity when the gearbox is lifted out.

Refitting the gearbox axis 3

Use this procedure to refit the gearbox.

Action

1

DANGER

Turn off all:



Note





4 Repair


Continued

Action Note

2

CAUTION


See


3

CAUTION



4

5


Remove any painting or other contamination from the assembly surfaces, with a knife.

Apply some grease on the o-ring before fitting it to the gearbox.

See the figure in:

•


6

7

8

9

10

11

Fit two guide pins in two opposite screw holes in the upper arm.

Remove the arm house cover.

Attach the rotation tool on the axis-3 motor.


Lift the gearbox onto the guide pins.


Note


12 Slide the gearbox into position while rotating the motor pinion to find the mating position.

Use a rotation tool .

Article number for the rotation tool is specified in


.

Tip

Two persons are required for this step since the upper arm is hanging freely in the air.

One person needs to hold the upper arm still while the other fits the gearbox into the upper arm.

13

14

15

Rotate the motor pinion and slide the gearbox into position.

Secure the gearbox with its attachment screws and washers .

See the figure in:

•



Remove the guide pins and replace them with the remaining attachment screws.





4 Repair


Continued

16

17

18

19

20

21

22

Action


Fit guide pins in the upper arm.

Note

See


.

Specified in


.

Move the upper arm to its mounting position.

(With the brakes of the axis 3 motor still released.)

Refit the upper arm to the lower arm with its attachment screws .

See the figure in:

•


Tightening torque:

• 35 Nm

Remove the guide pins and replace with the remaining attachment screws.

Remove the 24 VDC power supply.

Refit the upper armhouse cover with its attachment screws and washers.


Make sure that the cover is tightly sealed.

WARNING


B

23 Make sure that the armhouse cover is tightly fitted. If there is a gap between the cover and the robot, seal with Sikaflex 521 FC.

A xx0800000389

Parts:

• A: Cover

• B: Attachment screws M6x25, quality 8.8-A2F (10 pcs)





351

4 Repair


Continued

24

Action

Refit the two cable brackets and a cable strap to the lower arm.

Note

C

B

A


xx1100000946

A Cable bracket

B Cable bracket

C Cable strap

How to fill the gearbox with oil is described in section:

•


26

27

CSeal and paint the joints that have been opened. Also repair possible damages of the special Foundry Prime paint coat of the robot. See


.







28

DANGER



.




5 Calibration

5.1.1 Introduction and calibration terminology

5 Calibration

5.1 Introduction to calibration

5.1.1 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


Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools.

Calibration terminology

Term

Calibration method

Synchronization position

Calibration position

Standard calibration

Fine calibration

Reference calibration

Update revolution counter

Synchronization mark

Definition

A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines.

Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.

Known position of the complete robot that is used for calibration of the robot.

A generic term for all calibration methods that aim to move the robot to calibration position.

A calibration routine that generates a new zero position of the robot.

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 recalibrate the robot back to the same position as when the reference was stored.

This routine is more flexible compared to fine calibration 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.

A calibration routine to make a rough calibration of each manipulator axis.

Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position.




353

5 Calibration

5.1.2 Calibration methods

5.1.2 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 position.

Standard calibration data is found on the SMB

(serial measurement board) or EIB in the robot.

For robots with RobotWare 5.04 or older, the calibration data is delivered in a file, calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position.

Axis Calibration or Calibration Pendulum i

Absolute accuracy calibration (optional)

Based on standard calibration, and besides positioning the robot at synchronization position, the Absolute accuracy calibration also 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.

Absolute accuracy calibration data is found on the SMB (serial measurement board) in the robot.

For robots with RobotWare 5.05 or older, the absolute accuracy calibration data is delivered in a file, absacc.cfg, supplied with the robot at delivery. The file replaces the calib.cfg file and identifies motor positions as well as absolute accuracy compensation parameters.

A robot calibrated with absolute accuracy has a sticker next to the identification plate of the robot.

To regain 100% absolute accuracy performance, the robot must be recalibrated for absolute accuracy!

CalibWare xx0400001197 i

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.

Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant.

If no data is found related to standard calibration, Calibration Pendulum is used as default.





5 Calibration

5.1.2 Calibration methods

Continued

Brief description of calibration methods

Calibration Pendulum method

Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).

Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II

• Reference calibration

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

Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 4600 Foundry

Prime and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.

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


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.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute

Accuracy calibration is used as a TCP calibration. The CalibWare tool guides through the calibration process and calculates new compensation parameters.

This is further detailed in the Application manual - CalibWare Field 5.0

.

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 motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in the section

Special tools on page 394

.

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




355

5 Calibration

5.1.3 When to calibrate

5.1.3 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 recalibrated 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 360

. 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 reach ability of a robot is changed, it needs to be recalibrated for new resolver values.

If the robot has absolute accuracy calibration, it needs to be calibrated for new absolute accuracy.




5 Calibration

5.2.1 Synchronization marks and synchronization position for axes

5.2 Synchronization marks and axis movement directions

5.2.1 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, IRB 4600

IRB 4600-60/2.05

xx0800000312

A

B

C

Synchronization mark, axis 1







357

5 Calibration

5.2.1 Synchronization marks and synchronization position for axes

Continued

IRB 4600 - 60/2.05

xx1700001814

D

E

F




The two tips of the arrows should be inside the corresponding groove on the tilt housing when in synchronization position.




5 Calibration

5.2.2 Calibration movement directions for all axes

5.2.2 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, 6 axes

Note!

The graphic shows an IRB 7600. The positive direction is the same for all

6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction!

xx0200000089




359

5 Calibration

5.3 Updating revolution counters

5.3 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.

Coupled axes

When updating the revolution counters for a coupled axis, also the axis it is coupled to needs to be at its synchronization position for the update to be correct; i.e. axis

4 needs to be in synchronization position when updating axis 5 and 6.

With reversed coupled joints, the relationship is the opposite, i.e. axis 4 needs to be in synchronization position to update axis 3.

Coupled axes

Axis 4, 5, 6

Axis 5, 6

Axis 4, 3 x x x x x x x x x x x x x

Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.

1

2

3

Action Note

Select axis-by-axis motion mode.

Jog the manipulator to align the synchronization marks.

See

Synchronization marks and synchronization position for axes on page 357 .

When all axes are positioned, update the revolution counter.

Step 2 - Updating the revolution counter with the FlexPendant on page 361 .

Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important to make sure that axes 4 and 6 of the following mentioned manipulators are positioned correctly. The axes can be calibrated at the wrong turn, resulting in an incorrect manipulator calibration.

Make sure the axes are positioned according to the correct calibration values, not only according to the synchronization marks. The correct values are found on a label, located either on the lower arm, underneath the flange plate on the base or on the frame.

At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated.





5 Calibration


Continued

If one of the following mentioned axes are 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. This affects the following manipulators:

Manipulator variant

IRB 4600

Axis 4

No

Axis 6

No

If the synchronization marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the synchronization marks again (try both directions, if needed).

Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).

1

Action

On the ABB menu, tap Calibration .

xx1500000942





361

5 Calibration


Continued

2

Action

All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

xx1500000943

3 This step is valid for RobotWare 6.02 and later.

Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration.

Tap Manual Method (Advanced) .


362 xx1500000944




4

Action

A screen is displayed, tap Rev. Counters .

5 Calibration


Continued en0400000771

5

6

7

Tap Update Revolution Counters...

.

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

Select the axis to have its revolution counter updated by:

• Ticking in the box to the left

• Tapping Select all to update all axes.

Then tap Update .

A dialog box is displayed, warning that the updating operation cannot be undone:

• Tap Update to proceed with updating the revolution counters.

• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the selected revolution counters and removes the tick from the list of axes.

8

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury!

Check the synchronization position very carefully after each update. See

Checking the synchronization position on page 380

.




363

5 Calibration

5.4.1 Description of Axis Calibration

5.4 Calibrating with Axis Calibration method

5.4.1 Description of Axis Calibration

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.

The Axis Calibration procedure described roughly:

• 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.

• 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.

• The axis position is stored in RobotWare with an active choice from the operator.





5 Calibration


Continued

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 suspended.

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.


When reference calibration is performed, the robot is restored to the status given by the reference values.

Note

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

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.

In the mentioned routines, it is also possible to validate the calibration data.

Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to its calibration position during the calibration procedure.

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 allowed to be jogged will be given on the FlexPendant. These axes are marked with Unrestricted in the FlexPendant window.

How to calibrate a suspended robot

The IRB 4600 Foundry Prime is calibrated floor standing in factory, prior to shipping.





5 Calibration


Continued

To calibrate a suspended robot, reference calibration must be used. Reference values for a suspended robot must be created with the robot mounted at its working position, not standing on a floor.

To calibrate a suspended robot with the fine calibration routine, the robot must first be taken down and then be mounted standing on the floor.




5 Calibration

5.4.2 Calibration tools for Axis Calibration

5.4.2 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.

Calibration tool box,

Axis Calibration

Article number

3HAC062326-001

Note

Delivered as a set of calibration tools.

Required if Axis Calibration is the valid calibration method for the robot.

Contains a removal tool for removing special protection plugs on the turning disk.

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

B

C

Tube insert

Plastic protection

Steel spring ring





367

5 Calibration

5.4.2 Calibration tools for Axis 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




5 Calibration

5.4.3 Installation locations for the calibration tools

5.4.3 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.

xx1600000641





369

5 Calibration

5.4.3 Installation locations for the calibration tools

Continued

Spare parts xx1600000642

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, if needed.

Spare part

Protection cover and plug set

Protective plug on turning disc

Article number

3HAC060730-001

(protection type

Foundry Prime)

3HAC057511-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.

Only on IRB 4600 - 20/2.50.

Replace if damaged or missing.




5 Calibration

5.4.4 Axis Calibration - Running the calibration procedure

5.4.4 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.

Calibration tool box, Axis

Calibration

Article number

3HAC062326-001

Note




Required consumables

Consumable

Clean cloth

Spare parts

-


Spare part

Protection cover and plug set

Protective plug on turning disc

Article number

3HAC060730-001

(protection type

Foundry Prime)

3HAC057511-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.

Only on IRB 4600 - 20/2.50.


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. The routines are described in

Routines in the calibration procedure on page 365

.

2 Choose which axis/axes to calibrate.

3 The robot moves to synchronization position.

4 Validate the synchronization marks.





5 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.

Use the removal tool included in the calibration tool box to remove the special protection plug(s) on the turning disc.

IRB 4600 - 20/2.50: xx1700000905

When calibrating axis 6, push in the calibration tool into the turning disc until the snap ring engages, no further.

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.

Refit the protection plug(s) to the turning disc, push until the steel spring ring snaps into place.

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 robots 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.





5 Calibration


Continued

Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.

1

Action

On the ABB menu, tap Calibration .

Note xx1500000942

2 All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

xx1500000943





373

5 Calibration


Continued

3

Action Note

Calibration method used at factory for each axis is shown, as well as calibration method used for the robot during last field calibration.

Tap Run Calibration Method . The software will automatically call for the procedure for the valid calibration method.

The FlexPendant will give all information needed to proceed with Axis

Calibration.

xx1500000944

4 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 calibration procedure on the FlexPendant on page 371 .

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

FlexPendant has been released during robot movement.

Press and hold the three-position enabling device and press Play .

The RobotWare program is terminated with

PP to Main .

Remove the calibration tool, if it is installed, and restart the calibration procedure from the beginning. See

Starting the calibration procedure on page 373

.

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 359

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.





5 Calibration


Continued

However, SafeMove may generate other warning messages anytime during the

Axis Calibration routine.

Safety controller not synchronized - SafeMove message

1

Action

SafeMove generates the message "Safety controller not synchronized".

Note xx1500002480

2

3

Confirm unsynchronized state by pressing Acknowledge to continue Axis Calibration procedure.

Restart Axis Calibration procedure by pressing

Play .

Unsynchronized speed exceeded - SafeMove message while saving robot data

1

Action

SafeMove generates the message "Unsynchronized speed exceeded" while saving robot data.

Note

2

3 xx1500002481

Press Acknowledge to continue Axis Calibration procedure.


Play .





375

5 Calibration


Continued

Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine

1

Action

SafeMove generates the message "Unsynchronized time limit expired" (anytime).

Note

2

3 xx1500002482

Press OK to continue Axis Calibration procedure.


Play .

After calibration

1

2

Action

Check the o-ring on the fixed calibration pin.


Reinstall the protective cover on the fixed calibration pin on each axis, directly after the axis has been calibrated.

Replace the cover with new spare part, if missing or damaged.

Note xx1600002102

Protection cover and plug set: .

3HAC060730-001 (protection type

Foundry Prime)





5 Calibration


Continued

3

Action

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.

Tighten the plug lightly so that the sealing washer is just about fastened between the plug and the bushing. Then tighten 1/4 turn more.

Replace the plug and the sealing with new spare part, if missing or damaged.

Note

4 xx1600002103

Protection cover and plug set: .

3HAC060730-001 (protection type

Foundry Prime)

Refit the special protection plug to the turning disc using the tool included in the calibration tool box.

IRB 4600 - 20/2.50

5 Remove the tool from the protection plug.

xx1700000905

IRB 4600 - 20/2.50

xx1700000906




377

5 Calibration

5.5 Calibrating with Calibration Pendulum method

5.5 Calibrating with Calibration Pendulum method

Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools.




5 Calibration

5.6 Verifying the calibration

5.6 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.

1

2

3

4

Action Note

Run the calibration home position program twice.

Do not change the position of the robot axes after running the program!

See

Checking the synchronization position on page 380 .

Adjust the synchronization marks when the calibration is done, if necessary.

This is detailed in section

Synchronization marks and synchronization position for axes on page 357 .

Write down the values on a new label and stick it on top of the calibration label.

The label is located on the lower arm.

Remove any calibration equipment from the robot.




379

5 Calibration

5.7 Checking the synchronization position

5.7 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 Jogging window on the FlexPendant.

Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their synchronization position.

1

2

3

4

Action

On ABB menu tap Program editor .

Create a new program.

Use MoveAbsJ in the Motion&Proc menu.

Create the following program:

MoveAbsJ [[0,0,0,0,0,0],

[9E9,9E9,9E9,9E9,9E9,9E9]]

\NoEOffs, v1000, fine, tool0

Note

5

6

Run the program in manual mode.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See

Synchronization marks and synchronization position for axes on page 357

and


Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.

1

2

3

4

5

Action

On the ABB menu, tap Jogging .

Note

Tap Motion mode to select group of axes to jog.

Tap to select the axis to jog, axis 1, 2, or

3.

Manually run the robots axes to a position where the axis position value read on the

FlexPendant, is equal to zero.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See

Synchronization marks and synchronization position for axes on page 357

and





6 Decommissioning

6.1 Introduction



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.

General

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.




381


6.2 Environmental information

6.2 Environmental information

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

Hazardous material

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

Batteries, NiCad or Lithium

Copper

Cast iron/nodular iron

Steel

Neodymium

Plastic/rubber

Oil, grease

Aluminium

Nickel

Example application

Serial measurement board

Cables, motors

Base, lower arm, upper arm

Gears, screws, base frame, and so on.

Brakes, motors

Cables, connectors, drive belts, and so on.

Gearboxes

Covers, synchronization brackets

Turning disc (foundry)

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.






6.2 Environmental information

Continued

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.




383


6.3 Scrapping of robot

6.3 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries:

• 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.




7 Reference information

7.1 Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.




385


7.2 Applicable standards

7.2 Applicable standards

Note

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

Standards, EN ISO

The product is designed in accordance with the requirements of:

Standard

EN ISO 12100:2010

EN ISO 13849-1:2015

EN ISO 13850:2015

EN ISO 10218-1:2011

ISO 9787:2013

ISO 9283:1998

Description

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

Safety of machinery, safety related parts of control systems -

Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Robots for industrial environments - Safety requirements -Part

1 Robot

Robots and robotic devices -- Coordinate systems and motion nomenclatures

Manipulating industrial robots, performance criteria, and related test methods

Classification of air cleanliness

Ergonomics of the thermal environment - Part 1

EMC, Generic emission

EN ISO 14644-1:2015 i

EN ISO 13732-1:2008

EN 61000-6-4:2007 +

A1:2011

IEC 61000-6-4:2006 +

A1:2010

(option 129-1)

EN 61000-6-2:2005

IEC 61000-6-2:2005

EN IEC 60974-1:2012 ii

EN IEC 60974-10:2014

ii

EMC, Generic immunity

Arc welding equipment - Part 1: Welding power sources

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part

1 General requirements i ii

IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)

Only robots with protection Clean Room.

Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard

EN 614-1:2006 + A1:2009

EN 574:1996 + A1:2008

Description

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles

Safety of machinery - Two-hand control devices - Functional aspects - Principles for design






7.2 Applicable standards

Continued

Other standards

Standard

ANSI/RIA R15.06

ANSI/UL 1740

CAN/CSA Z 434-14

Description

Safety requirements for industrial robots and robot systems

Safety standard for robots and robotic equipment

Industrial robots and robot Systems - General safety requirements




387


7.3 Unit conversion

7.3 Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity

Length

Weight

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 g

1 bar

1 N

1 Nm

1 L

3.28 ft.

2.21 lb.

0.035 ounces

100 kPa

0.225 lbf

0.738 lbf-ft

0.264 US gal

39.37 in

14.5 psi





7.4 Screw joints

7.4 Screw joints

General

This section describes how to tighten the various types of screw joints on the IRB

4600 Foundry Prime.

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. 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.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 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.

Lubricant

Molycote 1000 (molybdenum disulphide grease)

Article number

3HAC042472-001

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.






7.4 Screw joints

Continued

• 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% !

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.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with allen head screws.

Note


Dimension

M5

M6

M8

M10

M12

M16

M20

M24

10

24

47

82

Tightening torque (Nm)

Class 8.8, oil-lubricated

Tightening torque (Nm) Tightening torque (Nm)



6 -

-

34

67

115

-

40

80

140

200

400

680

290

560

960

340

670

1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head screws.

Note


Dimension Tightening torque (Nm)

Class 10.9, lubricated i

28 M8


390


Class 12.9, lubricated

i

35





7.4 Screw joints

Continued

Dimension Tightening torque (Nm)

Class 10.9, lubricated i


Class 12.9, lubricated

i

M10

M12

M16

55

96

235

70

120

280

M20 460 550 i

M24 790 950

Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass .

Note


1/8

1/4

3/8

1/2

3/4

Dimension

15

20

40

70

Tightening torque Nm -

Nominal


Min.


Max.

12 8 15

10

15

30

55

20

25

50

90




391


7.5 Weight specifications

7.5 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 robot weighs 440 kg.






7.6 Standard tools

7.6 Standard tools

General

Contents, standard toolkit

1

1

1

1

1

1

1

1

1

1

Qty

1

1

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.

Tool

Ring-open-end spanner 8-19 mm

Socket head cap 2.5-17 mm

Torx socket no: 20-60

Torque wrench 10-100 Nm

Small screwdriver

Plastic mallet

Ratchet head for torque wrench 1/2"

Socket head cap no: 5, socket 1/2" bit L 20 mm



Small cutting plier

T-handle with ball head




393


7.7 Special tools

7.7 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


, and of special tools, listed directly in the instructions and also gathered in this section.

Measuring tools, play

The tools listed for measuring the play are used after service work on axes 5 and

6.

Description



Robot variant

IRB 4600 - 60/2.05, -45/2.05, -40/2.55

IRB 4600 - 20/2.50

Art. no.

3HAB1611-6

3HAB6337-1

Special tools

The following table specifies the special tools required during several of the service procedures. The tools may be ordered separately and are also specified directly in concerned instructions in the product manual.

Description Qty

Guide pins, removal/refitting of axis 1 gearbox

2 pcs

Guide pins, removal/refitting of axis 3 gearbox

2 pcs -

-

Art. no.

Oil change equipment

The following table specifies the oil change equipment. The tool is specified directly in concerned instructions in the product manual.

Description

Oil change equipment

Included parts Art. no.

• vacuum pump with regulator, hose and coupling

• couplings and adapters

• pump (manual) with hose and coupling

• graduated measuring glass

• oil gun

• user instructions.

3HAC021745-001

Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating the robot with the alternative method, Levelmeter Calibration.

Note Description

Angle bracket

Calibration bracket

Art. no.

68080011-LP

3HAC13908-9






7.7 Special tools

Continued

Description

Calibration tool ax1

Levelmeter 2000 kit

Measuring pin

Sensor fixture

Sensor plate

Sync. adapter

Art. no.

3HAC13908-4

6369901-347

3HAC13908-5

68080011-GM

3HAC0392-1

3HAC13908-1

Note

Includes one sensor.

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.

Always use the same calibration method as used at the factory.



Description

Calibration Pendulum toolkit

Art. no.

3HAC15716-1

Note

Complete kit that also includes operating manual.

Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating the robot with the Axis Calibration method.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.

Always use the same calibration method as used at the factory.



Description Art. no.

Calibration tool box, Axis Calibration

3HAC062326-

001

Note




Turning tool for suspended mounting

The following table specifies the lifting tool required when fitting the robot in a suspended position.


Turning tool (includes lifting instruction) 3HAC034766-001

Note

Valid for other designs than type C.






7.7 Special tools

Continued


Turning tool (includes lifting instruction

3HAC051688-001)

3HAC048502-001

Note

Valid for types B and C

Lifting accessories

This table specifies the lifting accessories required during several of the service procedures. The lifting accessories can be ordered separately and are also specified directly in concerned instructions.

Article no.

Note Description

Lifting accessory, axis 2

Lifting accessory, axis 3

Rotating lifting point

Qty

2 pcs For lifting of upper arm.

Dimension: M8.

Example: Gunnebo RLP

GrabiQ M8-10.

Special tools xx1100000564

This table specifies the special tools required during several of the service procedures. The tools are specified directly in concerned instructions.

Description

Guide for reduction gear

Qty

1

Article no.

3HACxxx

Used to guide axis-1 gear and frame during refitting.





7.8 Lifting accessories and lifting instructions

7.8 Lifting accessories and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure.

The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.

This implies that the instructions delivered with the lifting accessories should be stored for later reference.




397


8 Spare part lists

8.1 Spare part lists and illustrations

8 Spare part lists

8.1 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.myportal.abb.com

.




399


9 Circuit diagram

9.1 Circuit diagrams


9.1 Circuit diagrams

Overview

The circuit diagrams are not included in this manual, but are available for registered users on myABB Business Portal, www.myportal.abb.com

.

See the article numbers in the tables below.

Controllers

Product

Circuit diagram - IRC5

Circuit diagram - IRC5 Compact

Article numbers for circuit diagrams

3HAC024480-011

3HAC049406-003

Circuit diagram - IRC5 Panel Mounted Controller

3HAC026871-020

Circuit diagram - Euromap 3HAC024120-004

Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product


Circuit diagram - IRB 140 type C








Circuit diagram - IRB 1600/1660




Circuit diagram - IRB 4400/4450S


Circuit diagram - IRB 6400RF

Circuit diagram - IRB 6600 type A

Circuit diagram - IRB 6600 type B


3HAC031408-003

3HAC6816-3

3HAC025611-001

3HAC028647-009

3HAC036446-005

3HAC025691-001

3HAC025691-001

3HAC046307-003

3HAC2800-3

3HAC021351-003

3HAC039498-007

3HAC6670-3

3HAC029570-007

3HAC9821-1

3HAC029038-003

3HAC8935-1

3HAC13347-1

3HAC025744-001

3HAC13347-1

3HAC025744-001






9.1 Circuit diagrams

Continued

Product


Circuit diagram - IRB 6620 / IRB 6620LX


Circuit diagram - IRB 6650S




Circuit diagram - Product.ProductName

Circuit diagram - IRB 910SC


3HAC025090-001

3HAC025090-001

3HAC025744-001

3HAC13347-1

3HAC025744-001

3HAC025744-001

3HAC029940-001

3HAC043446-005

3HAC13347-1

3HAC025744-001

3HAC050778-003

3HAC056159-002




Index

Index

A

Absolute Accuracy, calibration, 355

air quality, 49

aluminum

disposal, 382

ambient humidity

operation, 55 storage, 55

ambient temperature


assembly instructions, 47

assessment of hazards and risks, 18

Axis Calibration, 364

calibration tool

article number, 367, 371

examining, 367

installation position, 369

overview of method, 364

procedure on FlexPendant, 371 protective cover and protection plug, 369, 371

B batteries

disposal, 382

handling, 36

battery pack

replacing, interval, 111

brakes

testing function, 35

C

cabinet lock, 23, 29

cabling, robot, 94 cabling between robot and controller, 94

calibrating

robot, 364

roughly, 360

calibrating robot, 364

calibration

Absolute Accuracy type, 354

rough, 360

standard type, 354

verification, 379

when to calibrate, 356

calibration, Absolute Accuracy, 355 calibration manuals, 355

calibration marks, 357

calibration position

jogging to, 380

scales, 357 calibration scales, 357

CalibWare, 354

carbon dioxide extinguisher, 20

cast iron

disposal, 382

cleaners

approved, 193 requirements, 193

cleaning, 191

climbing on robot, 23

Cold environments, 93

connecting the robot and controller, cabling, 94

connection




external safety devices, 24

copper

disposal, 382

D

danger levels, 39

detergents

approved, 193 requirements, 193

direction of axes, 359

E

enabling device, 28

environmental information, 382

ESD

damage elimination, 31 sensitive equipment, 31

expansion container

installing, 89

expected life, 112

external safety devices, 24

F

fire extinguishing, 20

FlexPendant

jogging to calibration position, 380

MoveAbsJ instruction, 380

updating revolution counters, 361

foundation

requirements, 54

G gearboxes

location of, 151

Gravity Alpha, 66

Gravity Beta, 65

grease

disposal, 382

H hanging

installed hanging, 23

hazardous material, 382

height

installed at a height, 23

hold-to-run, 28

HRA, 18

humidity


I

instructions for assembly, 47

integrator responsibility, 17

intervals for maintenance, 110

L labels

robot, 41

leak-down test, 196

lifting

accessory, 64

lifting accessory, 392

limitation of liability, 17

Lithium

disposal, 382

loads on foundation, 53

403

Index lubrication

amount in gearboxes, 151 type of lubrication, 151

M magnesium

disposal, 382

maintenance schedule, 110

MoveAbsJ instruction, 380

N

nation specific regulations, 17

negative directions, axes, 359

neodymium

disposal, 382

NiCad

disposal, 382

nodular iron

disposal, 382

O oil

amount in gearboxes, 151

disposal, 382

type of oil, 151

oil change

axis 1, floor mounted robots, 153

axis 1, suspended robots, 160

axis 2, 167

axis 3, 171

axis 4, 177

axis 5, 181 axis 6, 181

safety risks, 37

operating conditions, 55

options

expansion container, 89

P

paint surface damages, 150

pedestal

installed on pedestal, 23

plastic

disposal, 382

positive directions, axes, 359

pressurized components

air quality, 49

Foundry Prime, 48

product standards, 386

protection classes, 55 protection type, 55

protective equipment, 24 protective wear, 24

R

region specific regulations, 17

release brakes, 21

repair

painted surface, 150

replacing

xx, 143

requirements on foundation, 54

responsibility and validity, 17

revolution counters

storing on FlexPendant, 361

updating, 360

risk of tipping, 60

404 robot

labels, 41

protection class, 55 protection types, 55

symbols, 41

rubber

disposal, 382

S safety

brake testing, 35

ESD, 31

fire extinguishing, 20

moving robots, 25

release robot axes, 21

signals, 39 signals in manual, 39 symbols, 39

symbols on robot, 41

test run, 26

working range, 27

safety fence, 18

safety risk

electric parts, 29

hot parts, 32

hydraulic system, 33

installation, 23

oil change, 37

operational disturbance, 23

pneumatic system, 33

pressure relief valve, 34

service work, 23

voltage, 29

safety signals

in manual, 39

safety standards, 386

safety zones, 18

scales on robot, 357

schedule for maintenance, 110

screw joints, 389

sensitive points

Foundry Prime, 51

signals

safety, 39

special tools, 394

speed

adjusting, 93

stability, 60

standards, 386

ANSI, 387

CAN, 387

EN, 386

EN IEC, 386

EN ISO, 386

start of robot in cold environments, 93

steel

disposal, 382

storage conditions, 55

suspended mounting, 65

symbols

safety, 39

synchronization position, 360

sync marks, 357

system integrator requirements, 17

system parameter

Gravity Alpha, 66

Gravity Beta, 65




T temperatures


testing

brakes, 35

three-position enabling device, 28

tools

Axis Calibration, 395

calibration equipment, Levelmeter, 394

Calibration Pendulum, 395

for service, 394

torques on foundation, 53

troubleshooting

oil spills, 191

turning

accessory, 64

U

updating revolution counters, 360

Index

V

validity and responsibility, 17

velocity

adjusting, 93

verifying calibration, 379

W

weight, 52

base, 262–263

robot, 62, 74, 260, 280–281, 286, 288, 298–299, 330,

334, 340, 342, 348–350, 392

upper and lower arm, 339, 343

upper arm, complete, 270, 274

X xx

replacing, 143

Z zero position

checking, 380




405

ABB AB, Robotics

Robotics and Motion

S-721 68 VÄSTERÅS, Sweden

Telephone +46 (0) 21 344 400

ABB AS, Robotics


Nordlysvegen 7, N-4340 BRYNE, Norway

Box 265, N-4349 BRYNE, Norway

Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion

No. 4528 Kangxin Highway

PuDong 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



ABB IRB 4600 Foundry Prime Product Manual

Product manual

IRB 4600 Foundry Prime

Product manual

IRB 4600 Foundry Prime - 60/2.05

Table of contents

Overview of this manual

Product documentation

How to read the product manual

Important information about robots with protection type

Foundry Prime

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference information

8 Spare part lists

9 Circuit diagram

Index

Key Features

Related manuals

Frequently Answers and Questions

What are the main applications of the IRB 4600 Foundry Prime?

What are the benefits of using the IRB 4600 Foundry Prime?

What are the key features of the IRB 4600 Foundry Prime?

What is the IP rating of the IRB 4600 Foundry Prime?

Is the IRB 4600 Foundry Prime easy to use?

Table of contents

ABB IRB 4600 Foundry Prime Product Manual

Product manual

IRB 4600 Foundry Prime

Product manual

IRB 4600 Foundry Prime - 60/2.05

Table of contents

Overview of this manual

Product documentation

How to read the product manual

Important information about robots with protection type

Foundry Prime

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference information

8 Spare part lists

9 Circuit diagram

Index

Key Features

Related manuals

ABB

IRB 460-110/2.4

ABB

IRB 6640 Foundry Prime

ABB

IRB 120

ABB

IRB 7600 Series

ABB

IRB 4600 - 60/2.05

ABB

MTD 500

ABB

IRB 6660 - 130/3.1

ABB

IRB 7600 Series

ABB

IRB 760 Series

ABB

IRB1410

ABB

IRB 8700 - 550/4.20

ABB

IRB 140T type C

Frequently Answers and Questions

What are the main applications of the IRB 4600 Foundry Prime?

What are the benefits of using the IRB 4600 Foundry Prime?

What are the key features of the IRB 4600 Foundry Prime?

What is the IP rating of the IRB 4600 Foundry Prime?

Is the IRB 4600 Foundry Prime easy to use?

Table of contents