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IRB 4600 Foundry Prime
ABB IRB 4600 Foundry Prime User Manual
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ROBOTICS
Product
manual
IRB
4600
Foundry
Prime
2
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
9
Product Manual - IRB
11
Product Documentation
13
How to Read the Product Manual
15
Important Information about Robots with Protection Type Foundry Prime
16
1 Safety
17
General Safety Information
17
Limitation of Liability
17
Protective Stop and Emergency Stop
19
Safety Actions
20
Fire Extinguishing
20
Emergency Release of the Robot Axes
21
Make Sure that the Main Power Has Been Switched off
22
Safety Risks
23
Safety Risks During Installation and Service Work on Robots
23
Moving Robots Are Potentially Lethal
25
First Test Run May Cause Injury or Damage
26
Work Inside the Working Range of the Robot
27
Enabling Device and Hold-To-Run Functionality
28
Risks Associated with Live Electric Parts
29
The Unit Is Sensitive to ESD
31
Hot Parts May Cause Burns
32
Safety Risks Related to Pneumatic/Hydraulic Systems
33
Safety Risks with Pressure Relief Valve
34
Brake Testing
35
Safety Risks During Handling of Batteries
36
Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
37
Safety Signals and Symbols
39
Safety Signals in the Manual
39
Safety Symbols on Product Labels
41
2 Installation and Commissioning
47
Introduction
47
Installation and Operational Requirements for Foundry Prime Robots
48
Unpacking
52
Pre-Installation Procedure
52
Surface Inspection before Start-Up - Foundry Prime
56
Working Range and Type of Motion
57
Risk of Tipping/Stability
60
On-Site Installation
61
Lifting Robot with Roundslings
61
Lifting and Turning a Suspended Mounted Robot
64
Setting the System Parameters for a Suspended or Tilted Robot
65
Manually Releasing the Brakes
69
Orienting and Securing the Robot
72
Fitting Equipment on Robot
76
Surface Inspection before Start-Up - Foundry Prime
82
Loads Fitted to the Robot, Stopping Time and Braking Distances
83
Installation of Signal Lamp (Option)
84
Restricting the Working Range
85
Axes with Restricted Working Range
85
Mechanically Restricting the Working Range of Axis 1
86
Installing Options
89
Installing an Expansion Container
89
Robot in Hot Environments
92
Start of Robot in Hot Environments
92
Robot in Cold Environments
93
Start of Robot in Cold Environments
93
Electrical Connections
94
Robot Cabling and Connection Points
94
Customer Connection on Robot
96
Customer Connections on Upper Arm
99
Additional Installation (Foundry Prime)
101
Installation of IRB 4600 Foundry Prime in a Water Jet Application
101
Commissioning (Foundry Prime)
105
3 Maintenance
107
Introduction
107
Introduction for Foundry Prime Robots
108
Maintenance Schedule
109
Specification of Maintenance Intervals
109
Maintenance Schedule
110
Expected Component Life
112
Inspection Activities
113
Inspecting Oil Level, Axis 1 Gearbox
113
Inspecting the Oil Level, Axis 2 Gearbox
119
Inspecting the Oil Level, Axis 3 Gearbox
122
Inspecting the Oil Level, Axis 4 Gearbox
125
Inspecting Oil Level, Gearbox Axes 5 - 6
127
Inspecting the Cable Harness
131
Inspecting Information Labels
133
Inspecting the Mechanical Stop Pin, Axis 1
135
Inspecting Additional Mechanical Stops
139
Inspecting Dampers
141
Inspecting the Leak Proof O-Ring and Pressure Relief Valves
143
Inspecting Signal Lamp (Option)
146
Inspection of Air Hoses (Foundry Prime)
148
Inspection of Surface Treatment (Foundry Prime)
150
Replacement Activities
151
Type of Lubrication in Gearboxes
151
Changing the Oil, Axis 1 Gearbox on Floor Mounted Robots
153
Changing the Oil, Axis-1 Gearbox on Suspended Robots
160
Changing the Oil, Axis-2 Gearbox
167
Changing the Oil, Axis-3 Gearbox
171
Changing the Oil, Axis-4 Gearbox
177
Changing Oil, Axes-5 and -6 Gearboxes
181
Replacing SMB Battery
185
Analysis Activities
190
Analyzing the Water Content in Gearbox Oil
190
Cleaning Activities
191
Cleaning the IRB 4600 Foundry Prime
191
4 Repair
195
Introduction
195
General Procedures
196
Performing a Leak-Down Test
196
Mounting Instructions for Bearings
197
Mounting Instructions for Seals
199
Cut the Paint or Surface on the Robot before Replacing Parts
201
The Brake Release Buttons May be Jammed after Service Work
203
Complete Robot
204
Removing the Complete Cable Harness
204
Refitting the Complete Cable Harness
217
Replacement of Air Nipples and Hoses (Foundry Prime)
233
Replacing SMB Unit
245
Replacing the Brake Release Board
252
Replacing the Base
257
Upper Arm
267
Replacing the Complete Upper Arm
267
Replacing Complete Tubular Shaft Unit
277
Replacing Wrist Unit
284
Measuring the Play, Axis 5
290
Measuring the Play, Axis 6
292
Lower Arm
295
Replacing the Lower Arm
295
Frame and Base
301
Replacing Stop Pin Axis
301
Motors
305
Removing Motors
305
Refitting Motors
314
Adjusting the Play of Axis 4, 5 and 6 Motors
325
Gearboxes
326
Replacing Gearbox Axis 1
326
Replacing Gearbox Axis 2
336
Replacing Gearbox Axis 3
345
5 Calibration
353
Introduction to Calibration
353
Introduction and Calibration Terminology
353
Calibration Methods
354
When to Calibrate
356
Synchronization Marks and Axis Movement Directions
357
Synchronization Marks and Synchronization Position for Axes
357
Calibration Movement Directions for All Axes
359
Updating Revolution Counters
360
Calibrating with Axis Calibration Method
364
Description of Axis Calibration
364
Calibration Tools for Axis Calibration
367
Installation Locations for the Calibration Tools
369
Axis Calibration - Running the Calibration Procedure
371
Calibrating with Calibration Pendulum Method
378
Verifying the Calibration
379
Checking the Synchronization Position
380
6 Decommissioning
381
Introduction
381
Environmental Information
382
Scrapping of Robot
384
7 Reference Information
385
Introduction
385
Applicable Standards
386
Unit Conversion
388
Screw Joints
389
Weight Specifications
392
Standard Tools
393
Special Tools
394
Lifting Accessories and Lifting Instructions
397
8 Spare Part Lists
399
Spare Part Lists and Illustrations
399
Circuit Diagram
401
Index
403
4
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ABB IRB 4600 Foundry Prime Specifications
General
Payload Capacity
60 kg
Number of Axes
6
Protection Class
IP67
Controller
IRC5
Type
Industrial Robot
Mounting
Floor
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