abbrobotics productmanual irb4400 -...

ABB Robotics

Product manualIRB 4400

Trace back information:Workspace R13-1 version a6Checked in 2013-03-31Skribenta version 1184

Product manualIRB 4400/60

M2000, M2004

Document ID: 3HAC022032-001Revision: J

© Copyright 2004-2013 ABB. All rights reserved.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons or property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Additional copies of this manual may be obtained from ABB.The original language for this publication is English. Any other languages that aresupplied have been translated from English.

© Copyright 2004-2013 ABB. All rights reserved.ABB AB

Robotics ProductsSE-721 68 Västerås

Sweden

Table of contents9Overview of this manual ...................................................................................................................

12Product documentation, M2000/M2000A ........................................................................................13Product documentation, M2004 .......................................................................................................15How to read the product manual ......................................................................................................

171 Safety171.1 Introduction to safety information .........................................................................181.2 General safety information ..................................................................................181.2.1 Introduction to general safety information ....................................................191.2.2 Safety in the manipulator system ...............................................................201.2.3 Safety risks ............................................................................................201.2.3.1 Safety risks during installation and service work on manipulators .........231.2.3.2 CAUTION - Hot parts may cause burns! ...........................................241.2.3.3 Safety risks related to tools/work pieces ..........................................251.2.3.4 Safety risks related to pneumatic/hydraulic systems ..........................261.2.3.5 Safety risks during operational disturbances .....................................271.2.3.6 Risks associated with live electric parts ...........................................291.2.4 Safety actions .........................................................................................291.2.4.1 Safety fence dimensions ...............................................................301.2.4.2 Fire extinguishing ........................................................................311.2.4.3 Emergency release of the manipulator’s arm ....................................321.2.4.4 Brake testing ..............................................................................331.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................341.2.4.6 Safe use of the FlexPendant ..........................................................351.2.4.7 Work inside the manipulator's working range ...................................361.2.5 Safety stops ...........................................................................................361.2.5.1 What is an emergency stop? ..........................................................381.3 Safety related instructions ..................................................................................381.3.1 Safety signals in the manual ......................................................................401.3.2 Safety symbols on manipulator labels .........................................................451.3.3 DANGER - Moving manipulators are potentially lethal! ...................................461.3.4 DANGER - First test run may cause injury or damage! ...................................471.3.5 DANGER - Make sure that the main power has been switched off! ....................491.3.6 WARNING - The unit is sensitive to ESD! .....................................................511.3.7 WARNING - Safety risks during handling of batteries .....................................521.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......

552 Installation and commissioning552.1 Introduction ......................................................................................................562.2 Installation and operational requirements for Foundry Prime robots ............................592.3 Unpacking .......................................................................................................592.3.1 Pre-installation procedure .........................................................................622.3.2 Working range, IRB 4400 ..........................................................................632.4 On-site installation ............................................................................................632.4.1 Lifting robot with roundslings ....................................................................662.4.2 Manually releasing the brakes ...................................................................692.4.3 Orienting and securing the robot ................................................................722.4.4 Fitting equipment on robot ........................................................................752.4.5 Loads ....................................................................................................762.4.6 Installation of signal lamp (option) ..............................................................772.5 Restricting the working range ..............................................................................772.5.1 Introduction ............................................................................................782.5.2 Mechanically restricting the working range of axis 1 ......................................812.5.3 Mechanically restricting the working range of axis 2 ......................................842.5.4 Electrically restricting the working range of axis 3 .........................................

3HAC022032-001 Revision: J 5© Copyright 2004-2013 ABB. All rights reserved.

Table of contents

862.5.5 Unlimited working range ...........................................................................882.5.6 Risk of tipping/stability .............................................................................892.6 Electrical connections ........................................................................................892.6.1 Customer connection on robot ...................................................................912.6.2 Customer connections on upper arm ..........................................................932.7 Additional installation, Foundry Prime ...................................................................932.7.1 Installation of IRB 4400 in a water jet application ...........................................972.7.2 Commissioning (Foundry Prime) ................................................................

993 Maintenance993.1 Introduction ......................................................................................................

1003.2 Introduction for Foundry Prime robots ...................................................................1013.3 Maintenance schedule .......................................................................................1013.3.1 Specification of maintenance intervals ........................................................1023.3.2 Maintenance schedule .............................................................................1043.4 General maintenance activities ............................................................................1043.4.1 Inspection of mechanical stop, axis 1 ..........................................................1063.4.2 Inspection of air hoses (Foundry Prime) ......................................................1073.4.3 Inspection of surface treatment (Foundry Prime) ...........................................1083.4.4 Replacing the SMB battery ........................................................................1103.4.5 Cleaning, robot ......................................................................................1153.5 Changing and inspecting oil ................................................................................1153.5.1 Type of lubrication in gearboxes ................................................................1163.5.2 Inspection of oil levels ..............................................................................1193.5.3 Oil change, gearbox axis 4 ........................................................................1223.5.4 Oil change, gearbox axis 5 and 6 (all robot versions) .....................................1253.6 Service Information System, M2000 ......................................................................1253.6.1 Using the SIS system ...............................................................................1263.6.2 Description of Service Information System (SIS) ...........................................1293.6.3 SIS system parameters ............................................................................1313.6.4 Setting the SIS parameters .......................................................................1333.6.5 Reading the SIS output logs ......................................................................1343.6.6 Exporting the SIS data .............................................................................

1354 Repair1354.1 Introduction ......................................................................................................1364.2 General procedures ...........................................................................................1364.2.1 Mounting instructions for bearings .............................................................1384.2.2 Mounting instructions for seals ..................................................................1404.2.3 Replacing parts on Foundry Prime robots ....................................................1424.2.4 Performing a leak-down test .....................................................................1434.3 Complete robot .................................................................................................1434.3.1 Replacement of cable harness, axes 1-3 ......................................................1484.3.2 Replacement of cable harness, axes 4-6 ......................................................1544.3.3 Replacement of complete arm system .........................................................1594.4 Upper arm .......................................................................................................1594.4.1 Replacement of complete upper arm ...........................................................1644.4.2 Replacement of wrist unit .........................................................................1684.4.3 Replacement of arm house unit, axis 4 ........................................................1704.4.4 Replacement of mechanical stop, axis 4 ......................................................1734.4.5 Replacement of signal cabling, upper arm (option 042) ...................................1774.4.6 Measuring the play, axis 5 .........................................................................1794.4.7 Measuring the play, axis 6 .........................................................................1824.5 Lower arm .......................................................................................................1824.5.1 Replacement of lower arm ........................................................................1864.5.2 Replacement of tie rod .............................................................................1904.5.3 Replacement of parallel arm / Replacement of bearing ...................................1944.6 Frame and base ................................................................................................1944.6.1 Replacement of balancing device ...............................................................

6 3HAC022032-001 Revision: J© Copyright 2004-2013 ABB. All rights reserved.

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2024.6.2 Replacement of serial measurement unit .....................................................2064.6.3 Replacement of pushbutton unit for brake release .........................................2094.6.4 Replacement of mechanical stop pin, axis 1 .................................................2114.7 Motors ............................................................................................................2114.7.1 Replacement of motor, axis 1 ....................................................................2164.7.2 Replacement of motor, axis 2 ....................................................................2204.7.3 Replacement of motor, axis 3 ....................................................................2244.7.4 Adjustment of motors, axes 1-3 ..................................................................2264.7.5 Removal of motor, axes 4, 5 and 6 ..............................................................2284.7.6 Refitting of motor, axis 4 ...........................................................................2314.7.7 Refitting of motor, axis 5 ...........................................................................2344.7.8 Refitting of motor, axis 6 ...........................................................................2374.8 Gearboxes .......................................................................................................2374.8.1 Replacement of gearbox unit, axes 1-2-3 .....................................................2424.8.2 Adjusting play on axis 4, intermediate gear ..................................................2444.9 Additional repair routines for Foundry Prime ..........................................................2444.9.1 Repair routines .......................................................................................

2535 Calibration2535.1 Introduction .....................................................................................................2545.2 Calibration methods ...........................................................................................2565.3 Calibration scale and correct axis position .............................................................2585.4 Calibration movement directions for all axes ..........................................................2595.5 Updating revolution counters ...............................................................................2635.6 Checking the calibration position ..........................................................................2655.7 Additional calibration instruction, IRB 4400 ............................................................

2676 Decommissioning2676.1 Environmental information ..................................................................................

2697 Reference information2697.1 Introduction ......................................................................................................2707.2 Applicable safety standards ................................................................................2727.3 Unit conversion .................................................................................................2737.4 Screw joints ....................................................................................................2767.5 Weight specifications .........................................................................................2777.6 Standard tools ..................................................................................................2787.7 Special tools ....................................................................................................2797.8 Lifting accessories and lifting instructions ..............................................................

2818 Part list2818.1 Introduction ......................................................................................................2828.2 Manipulator ......................................................................................................2868.3 Upper arm part, axes 4-6 ....................................................................................2888.4 Serial measurement unit .....................................................................................2898.5 Position switch, axis 1 ........................................................................................

2919 Exploded views2919.1 Introduction ......................................................................................................2929.2 Exploded views .................................................................................................

30110 Circuit diagram30110.1 About circuit diagrams .......................................................................................

303Index


Table of contents

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Overview of this manualAbout 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 manual also contains reference information for all procedures detailed in themanual.

UsageThis manual should be used during

• installation, from lifting the robot to its work site and securing it to thefoundation to making it ready for operation

• maintenance work• repair work.

Who should read this manual?This manual is intended for:

• installation personnel• maintenance personnel• repair personnel.

PrerequisitesA maintenance/repair/installation craftsman working with an ABB Robot must:

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

Organization of chaptersThe manual is organized in the following chapters:

ContentsChapter

Safety informationSafety, service

Information about installation of the robot.Installation and commissioning

Information about maintenance work, including mainten-ance schedules.

Maintenance

Information about repair work.Repair

Procedures that does not require specific calibrationequipment. General information about calibration.

Calibration information

Environmental information about the robot and its compon-ents.

Decommissioning

Useful information when performing installation, mainten-ance or repair work (lists of necessary tools, referencedocuments, safety standards)

Reference information

Complete list of robot parts, shown in the partlistPart list

Continues on next page3HAC022032-001 Revision: J 9


Overview of this manual

ContentsChapter

Detailed illustrations of the robot with reference numbersto the part list.

Exploded views

Reference to the circuit diagram for the robot.Circuit diagram

References

NoteDocument IDDocument name

3HAC9117-1Product specification - IRB 4400

3HAC9821-1Circuit diagram, IRB 4400

M20043HAC021313-001Product manual - IRC5

M20043HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC16578-1Operating manual - Calibration Pendulum

3HAC030421-001Application manual - CalibWare Field 5.0

3HAC042927-001Technical reference manual - Lubrication in gear-boxes

3HAC025709-001Operating manual - Service Information System

M20043HAC021395-001Application manual - Additional axes and standalone controller

Revisions

DescriptionRevision

First edition.-Replaces previous manuals:

• Installation and Commissioning Manual• Maintenance Manual• Repair Manual, part 1• Repair Manual, part 2.

Changes made in the material from the previous manuals:• Model M2004 implemented.

Chapter Safety, service replaced with chapter Safety.AChapter Calibration replaced with chapter Calibration information.Removed chapter Calibration, M2004.Section Document references is completed with article numbers for calibrationmanuals.

Yaskawa motors been added.B

Robot model IRB 4450S added.C

Foundry Prime (Water jet application) added.D

Cleanroom added.EChanges made in:

• Prerequisites in section Overview• Oil change in section Maintenance

Content updated in chapter/section:• Section What is an emergency stop? added to chapter Safety• Maintenance/Maintenance schedule: Interval for replacement of battery

pack changed• Maintenance/Cleaning of robot

F

Continues on next page10 3HAC022032-001 Revision: J



Continued

DescriptionRevision

Missing spare part in chapter Spare parts, section Upper arm, axes 4-6, added:• Item 29, Gear axis 6

G

This revision includes the following addtions and/or changes:• Inspection of surface treatment added to maintenance schedule (Foundry

Prime)• Circuit diagrams are not included in this document but delivered as

separate files.• List of applicable safety standards updated.• Decommissioning chapter added.

The chapter Safety updated with:• Updated safety signal graphics for the levels Danger and Warning.

Safety signals in the manual:• New safety labels on the manipulator.• Revised terminology: robot replaced with manipulator.

H

This revision includes the following updates:• All information about IRB 4400-45, IRB 4400-L10, IRB 4400-L30, IRB

4400-S and IRB 4450S is removed from the manual.• A new block, about general illustrations, added in section How to read

the product manual on page 15.• Some general tightening torques have been changed/added, see updated

values in Screw joints on page 273.• Added WARNING - Safety risks during handling of batteries on page51.• All data about type of lubrication in gearboxes is moved from the

manual to a separate lubrication manual, see Type and amount of oil ingearboxes on page 115.

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

J



Continued

Product documentation, M2000/M2000AGeneral

The complete product documentation kit for the M2000 robot system, includingcontroller, robot and any hardware option, consists of the manuals listed below:

Product manualsManipulators, controllers, DressPack/SpotPack, and most other hardware will bedelivered 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 exploded views (or references to separate spare parts

lists).• Circuit diagrams (or references to circuit diagrams).

Software manualsThe software documentation consists of a wide range of manuals, ranging frommanuals for basic understanding of the operating system to manuals for enteringparameters during operation.A complete listing of all available software manuals is available from ABB.

Controller hardware option manualEach hardware option for the controller is supplied with its own documentation.Each document set contains the types of information specified below:

• Installation information• Repair information• Maintenance information

In addition, spare part information is supplied for the entire option.


Product documentation, M2000/M2000A

Product documentation, M2004Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listingis based on the type of information in the documents, regardless of whether theproducts are standard or optional.All documents listed can be ordered from ABB on a DVD. The documents listedare valid for M2004 manipulator systems.

Product manualsManipulators, controllers, DressPack/SpotPack, and most other hardware will bedelivered 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 exploded views (or references to separate spare parts

lists).• Circuit diagrams (or references to circuit diagrams).

Technical reference manualsThe technical reference manuals describe reference information for roboticsproducts.

• Technical reference manual - Lubrication in gearboxes: Description of typesand volumes of lubrication for the manipulator gearboxes.

• Technical reference manual - RAPID overview: An overview of the RAPIDprogramming language.

• Technical referencemanual - RAPID Instructions, Functions and Data types:Description and syntax for all RAPID instructions, functions, and data types.

• Technical reference manual - RAPID kernel: A formal description of theRAPID programming language.

• Technical reference manual - System parameters: Description of systemparameters and configuration workflows.

Application manualsSpecific applications (for example software or hardware options) are described inApplication manuals. An application manual can describe one or severalapplications.



Product documentation, M2004

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, DVD with PC software).• How to install included or required hardware.• How to use the application.• Examples of how to use the application.

Operating manualsThe operating manuals describe hands-on handling of the products. The manualsare aimed at those having first-hand operational contact with the product, that isproduction cell operators, programmers, and trouble shooters.The group of manuals includes (among others):

• Operating manual - Emergency safety information• Operating manual - General safety information• Operating manual - Getting started, IRC5 and RobotStudio• Operating manual - Introduction to RAPID• Operating manual - IRC5 with FlexPendant• Operating manual - RobotStudio• Operatingmanual - Trouble shooting IRC5, for the controller and manipulator.


Product documentation, M2004

Continued

How to read the product manualReading the procedures

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

References to figuresThe procedures often include references to components or attachment pointslocated on the manipulator/controller. The components or attachment points aremarked with italic text in the procedures and completed with a reference to thefigure where the current component or attachment point is shown.The denomination in the procedure for the component or attachment pointcorresponds to the denomination in the referenced figure.The table below shows an example of a reference to a figure from a step in aprocedure.

Note/IllustrationAction

Shown in the figure Location ofgearbox on page xx.

Remove the rear attachment screws, gearbox.8.

References to required equipmentThe procedures often include references to equipment (spare parts, tools, etc.)required for the different actions in the procedure. The equipment is marked withitalic text in the procedures and completed with a reference to the section wherethe equipment is listed with further information, that is article number anddimensions.The designation in the procedure for the component or attachment pointcorresponds to the designation in the referenced list.The table below shows an example of a reference to a list of required equipmentfrom a step in a procedure.


Art. no. is specified in Requiredequipment on page xx.

Fit a new sealing, axis 2 to the gearbox.3.

Safety informationThe manual includes a separate safety chapter that must be read through beforeproceeding with any service or installation procedures. All procedures also includespecific safety information when dangerous steps are to be performed.Read more in the chapter Safety on page 17.

IllustrationsThe robot is illustrated with general figures that does not take painting or protectiontype in consideration.Likewise certain work methods or general information, that is valid for several robotmodels, can be illustrated with pictures that show a different robot model that theone described in the current manual.


How to read the product manual

1 Safety1.1 Introduction to safety information

OverviewThe safety information in this manual is divided into two categories:

• General safety aspects, important to attend to before performing any servicework on the robot. These are applicable for all service work and are foundin General safety information on page 18.

• Specific safety information, pointed out in the procedures. How to avoid andeliminate the danger is either described directly in the procedure, or in specificinstructions in the section Safety related instructions on page 38.


1 Safety1.1 Introduction to safety information

1.2 General safety information

1.2.1 Introduction to general safety information

DefinitionsThis section details general safety information for personnel performing installation,repair and maintenance work.

SectionsThe general safety information is divided into the following sections.

ContainingContents• safety, service• limitation of liability• related information

General information

• safety risks during installation or service• risks associated with live electrical parts

Safety risks lists dangers relevant whenworking with the product. The dangers aresplit into different categories.

• fire extinguishing• safe use of the FlexPendant

Safety actions describes actions whichmay be taken to remedy or avoid dangers.

• stopping functions• description of emergency stop• description of safety stop• description of safeguarding

Safety stops describes different types ofstops.


1 Safety1.2.1 Introduction to general safety information

1.2.2 Safety in the manipulator system

Validity and responsibilityThe information does not cover how to design, install and operate a completesystem, nor does it cover all peripheral equipment that can influence the safety ofthe entire system. To protect personnel, the complete system must be designedand installed in accordance with the safety requirements set forth in the standardsand regulations of the country where the manipulator is installed.The users of ABB industrial manipulators are responsible for ensuring that theapplicable safety laws and regulations in the country concerned are observed andthat the safety devices necessary to protect people working with the manipulatorsystem are designed and installed correctly. Personnel working with manipulatorsmust be familiar with the operation and handling of the industrial manipulator asdescribed in the applicable documents, for example:

• Operating manual - IRC5 with FlexPendant• Product manual

Connection of external safety devicesApart from the built-in safety functions, the manipulator is also supplied with aninterface for the connection of external safety devices. An external safety functioncan interact with other machines and peripheral equipment via this interface. Thismeans that control signals can act on safety signals received from the peripheralequipment as well as from the manipulator.

Limitation of liabilityAny information given in this manual regarding safety must not be construed as awarranty by ABB that the industrial manipulator will not cause injury or damageeven if all safety instructions are complied with.

Related information

SectionDetailed in documentType of information

Installation andcommissioning

Product manual for the manipulatorInstallation of safety devices

Operating modesOperatingmanual - IRC5with FlexPend-ant

Changing operating modes

Installation andcommissioning

Product manual for the manipulatorRestricting the working space


1 Safety1.2.2 Safety in the manipulator system

1.2.3 Safety risks

1.2.3.1 Safety risks during installation and service work on manipulators

OverviewThis section includes information on general safety risks to be considered whenperforming installation and service work on the manipulator.These safety instructions have to be read and followed by any person who dealswith the installation and maintenance of the manipulator. Only persons who knowthe manipulator and are trained in the operation and handling of the manipulatorare allowed to maintain the manipulator. Persons who are under the influence ofalcohol, drugs or any other intoxicating substances are not allowed to maintain,repair, or use the manipulator.

General risks during installation and service• The instructions in the product manual in the chapter Installation and

commissioning must always be followed.• Emergency stop buttons must be positioned in easily accessible places so

that the manipulator can be stopped quickly.• Those in charge of operations must make sure that safety instructions are

available for the installation in question.• Those who install the manipulator must have the appropriate training for the

equipment in question and in any safety matters associated with it.

Spare parts and special equipmentABB does not supply spare parts and special equipment which have not beentested and approved by ABB. The installation and/or use of such products couldnegatively affect the structural properties of the manipulator and as a result of thataffect the active or passive safety operation. ABB is not liable for damages causedby the use of non-original spare parts and special equipment. ABB is not liable fordamages or injuries caused by unauthorized modifications to the manipulatorsystem.

Nation/region specific regulationsTo prevent injuries and damages during the installation of the manipulator, theregulations applicable in the country concerned and the instructions of ABBRobotics must be complied with.

Non-voltage related risks• Safety zones, which must be crossed before admittance, must be set up in

front of the manipulator's working space. Light beams or sensitive mats aresuitable devices.

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



1 Safety1.2.3.1 Safety risks during installation and service work on manipulators

• The axes are affected by the force of gravity when the brakes are released.In addition to the risk of being hit by moving manipulator parts, there is a riskof being crushed by the parallel arm (if there is one).

• Energy stored in the manipulator for the purpose of counterbalancing certainaxes may be released if the manipulator, or parts thereof, are dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.• Be aware of stored heat energy in the controller.• Never use the manipulator as a ladder, which means, do not climb on the

manipulator motors or other parts during service work. There is a seriousrisk of slipping because of the high temperature of the motors and oil spillsthat can occur on the manipulator.

To be observed by the supplier of the complete system• The supplier of the complete system must ensure that all circuits used in the

safety function are interlocked in accordance with the applicable standardsfor that function.

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

Complete manipulator

DescriptionSafety risk

CAUTION

Motors and gears are HOT after running themanipulator! Touching motors and gears mayresult in burns!With a higher environment temperature, moresurfaces on the manipulator will get HOT andmay also result in burns.

Hot components!

WARNING

Take any necessary measures to ensure thatthe manipulator does not collapse as partsare removed, e.g. secure the lower arm ac-cording to repair instruction if removing mo-tor, axis 2.

Removed parts may result in collapse ofmanipulator!

WARNING

If the internal cables for the measurementsystem have been disconnected during repairor maintenance, then the revolution countersmust be updated.

Removed cables to the measurement sys-tem




Continued

Cabling


CAUTION

The cable packs are sensitive to mechanicaldamage! They must be handled with care,especially the connectors, in order to avoiddamaging them!

Cable packs are sensitive to mechanicaldamage!

Gearboxes and motors


CAUTION

Whenever parting/mating motor and gearbox,the gears may be damaged if excessive forceis used!

Gears may be damaged if excessive forceis used!

Balancing device


WARNING

Do not under any circumstances, deal withthe balancing device in any other way thanthat detailed in the product documentation!For example, attempting to open the balan-cing device is potentially lethal!

Dangerous balancing device!



Continued

1.2.3.2 CAUTION - Hot parts may cause burns!

DescriptionDuring normal operation, many manipulator parts become hot, especially the drivemotors and gears. Sometimes areas around these parts also become hot. Touchingthese may cause burns of various severity.Because of a higher environment temperature, more surfaces on the manipulatorget hot and may result in burns.

EliminationThe instructions below detail how to avoid the dangers specified above:

InfoAction

Always use your hand, at some distance, tofeel if heat is radiating from the potentiallyhot component before actually touching it.

1

Wait until the potentially hot component hascooled if it is to be removed or handled in anyother way.

2


1 Safety1.2.3.2 CAUTION - Hot parts may cause burns!

1.2.3.3 Safety risks related to tools/work pieces

Safe handlingIt must be possible to safely turn off tools, such as milling cutters, etc. Make surethat guards remain closed until the cutters stop rotating.It should be possible to release parts by manual operation (valves).

Safe designGrippers/end effectors must be designed so that they retain work pieces in theevent of a power failure or a disturbance to the controller.Unauthorized modifications of the originally delivered manipulator 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 could be affected.

CAUTION

Ensure that a gripper is prevented from dropping a work piece, if such is used.


1 Safety1.2.3.3 Safety risks related to tools/work pieces

1.2.3.4 Safety risks related to pneumatic/hydraulic systems

GeneralSpecial safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from thepower supply must be provided with clearly visible drain facilities and a warningsign that indicates the need for pressure relief before adjustments or performingany maintenance on the manipulator 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 checked 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.


1 Safety1.2.3.4 Safety risks related to pneumatic/hydraulic systems

1.2.3.5 Safety risks during operational disturbances

General• The industrial manipulator is a flexible tool that can be used in many different

industrial applications.• All work must be carried out professionally and in accordance with the

applicable safety regulations.• Care must be taken at all times.

Qualified personnelCorrective maintenance must only be carried out by qualified personnel who arefamiliar with the entire installation as well as the special risks associated with itsdifferent parts.

Extraordinary risksIf the working process is interrupted, extra care must be taken due to risks otherthan those associated with regular operation. Such an interruption may have to berectified manually.


1 Safety1.2.3.5 Safety risks during operational disturbances

1.2.3.6 Risks associated with live electric parts

Voltage related risks, generalWork on the electrical equipment of the manipulator must be performed by aqualified electrician in accordance with electrical regulations.

• Although troubleshooting may, on occasion, need to be carried out while thepower supply is turned on, the robot must be turned off (by setting the mainsswitch to OFF) when repairing faults, disconnecting electric leads anddisconnecting or connecting units.

• The mains supply to the robot must be connected in such a way that it canbe turned off from outside the robot’s working space.

The necessary protection for the electrical equipment and manipulator systemduring construction, commissioning, and maintenance is guaranteed if the validregulations are followed.All work must be performed:

• by qualified personnel• on machine/manipulator system in deadlock• in an isolated state, disconnected from power supply, and protected against

reconnection

Voltage related risks, IRC5 controllerA danger of high voltage is associated with, for example, the following parts:

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

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

• The mains supply/mains 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.



1 Safety1.2.3.6 Risks associated with live electric parts

Voltage related risks, manipulatorA danger of high 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).See chapter Installation and commissioning on page 55.

Voltage related risks, tools, material handling devices, etc.Tools, material handling devices, etc., may be live even if the robot system is inthe OFF position. Power supply cables which are in motion during the workingprocess may be damaged.


1 Safety1.2.3.6 Risks associated with live electric parts

Continued

1.2.4 Safety actions

1.2.4.1 Safety fence dimensions

GeneralInstall a safety cell around the manipulator to ensure safe manipulator installationand operation.

DimensioningDimension the fence or enclosure to enable it to withstand the force created if theload being handled by the manipulator is dropped or released at maximum speed.Determine the maximum speed from the maximum velocities of the manipulatoraxes and from the position at which the manipulator 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 malfunctioningrotating tool or other device fitted to the manipulator.


1 Safety1.2.4.1 Safety fence dimensions

1.2.4.2 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in themanipulator system (manipulator or controller)!


1 Safety1.2.4.2 Fire extinguishing

1.2.4.3 Emergency release of the manipulator’s arm

DescriptionIn an emergency situation, any of the manipulator's axes may be released manuallyby pushing the brake release buttons on the manipulator.How to release the brakes is detailed in the section:

• Manually releasing the brakes on page 66.The manipulator arm may be moved manually on smaller manipulator models, butlarger models may require using an overhead crane or similar equipment.

Increased injuryBefore releasing the brakes, make sure that the weight of the arms does notincrease the pressure on the trapped person, further increasing any injury!


1 Safety1.2.4.3 Emergency release of the manipulator’s arm

1.2.4.4 Brake testing

When to testDuring operation, the holding brake of each axis normally wears down. A test canbe performed to determine whether the brake can still perform its function.

How to testThe function of the holding brake of each axis motor may be checked as describedbelow:

1 Run each manipulator axis to a position where the combined weight of themanipulator arm and any load is maximized (max. static load).

2 Switch the motor to the MOTORS OFF position with the operating modeselector on the controller.

3 Check that the axis maintains its position.If the manipulator does not change position as the motors are switched off,then the brake function is adequate.


1 Safety1.2.4.4 Brake testing

1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s"

Note

Do not change Transm gear ratio or other kinematic system parameters fromthe FlexPendant or a PC. This will affect the safety function "Reduced speed 250mm/s".


1 Safety1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s"

1.2.4.6 Safe use of the FlexPendant

Enabling deviceThe enabling device is a manually operated, constant pressure push-button which,when continuously activated in one position only, allows potentially hazardousfunctions but does not initiate them. In any other position, hazardous functions arestopped safely.The enabling device is of a specific type where you must press the push-buttononly half-way to activate it. In the fully in and fully out positions, manipulatoroperation is impossible.

Note

The enabling device is a push-button located on the side of the FlexPendantwhich, when pressed halfway in, switches the system to MOTORS ON. Whenthe enabling device is released or pushed all the way in, the manipulator switchesto the MOTORS OFF state.To ensure safe use of the FlexPendant, 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 manipulator to move.• Anyone entering the manipulator working space must always bring the

FlexPendant with him/her. This is to prevent anyone else from taking controlof the manipulator without his/her knowledge.

Hold-to-run functionThe hold-to-run function allows movement when a button connected to the functionis actuated manually and immediately stops any movement when released. Thehold-to-run function can only be used in manual mode.How to operate the hold-to-run function for IRC5 is described in Operatingmanual - IRC5 with FlexPendant.


1 Safety1.2.4.6 Safe use of the FlexPendant

1.2.4.7 Work inside the manipulator's working range

WARNING

If work must be carried out within the manipulator’s work area, the followingpoints must be observed:

• The operating mode selector on the controller must be in the manual modeposition to render the enabling device operational and to block operationfrom a computer link or remote control panel.

• The manipulator’s speed is limited to max. 250 mm/s when the operatingmode selector is in the position Manual mode with reduced speed. Thisshould be the normal position when entering the working space.The position Manual mode with full speed (100%) may only be used bytrained personnel who are aware of the risks that this entails. Manual modewith full speed (100%) is not available in USA or Canada.

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

• Test the motor brake on each axis, according to the section Brake testingon page 32.

WARNING

NEVER, under any circumstances, stay beneath any of the manipulator’s axes!There is always a risk that the manipulator will move unexpectedly whenmanipulator axes are moved using the enabling device or during other workinside the manipulator’s working range.


1 Safety1.2.4.7 Work inside the manipulator's working range

1.2.5 Safety stops

1.2.5.1 What is an emergency stop?

Definition of emergency stopAn emergency stop is a state that overrides any other manipulator control,disconnects drive power from the manipulator motors, stops all moving parts, anddisconnects power from any potentially dangerous functions controlled by themanipulator system.An emergency stop state means that all power is disconnected from the manipulatorexcept for the manual brake release circuits. You must perform a recoveryprocedure, i.e, resetting the emergency stop button and pressing the Motors Onbutton, in order to return to normal operation.The manipulator system can be configured so that the emergency stop results ineither:

• An uncontrolled stop, immediately stopping the manipulator actions bydisconnecting power from the motors.

• A controlled stop, stopping the manipulator actions with power available tothe motors so that the manipulator path can be maintained. When completed,power is disconnected from the motors.

The default setting is an uncontrolled stop. However, controlled stops are preferredsince they minimize extra, unnecessary wear on the manipulator and the actionsneeded to return the manipulator system back to production. Please consult yourplant or cell documentation to see how your manipulator system is configured.

Note

The emergency stop function may only be used for the purpose and under theconditions for which it is intended.

Note

The emergency stop function is intended for immediately stopping equipmentin the event of an emergency.

Note

Emergency stop should not be used for normal program stops as this causesextra, unnecessary wear on the manipulator.For how to perform normal program stops, see section Stopping programs inOperating manual - IRC5 with FlexPendant.



1 Safety1.2.5.1 What is an emergency stop?

Classification of stopsThe safety standards that regulate automation and manipulator equipment definecategories in which each type of stop applies:

... then it is classified as...If the stop is...

category 0 (zero)uncontrolled

category 1controlled

Emergency stop devicesIn a manipulator system there are several emergency stop devices that can beoperated in order to achieve an emergency stop. There are emergency stop buttonsavailable on the FlexPendant and on the controller cabinet (on the Control Moduleon a Dual Cabinet Controller). There can also be other types of emergency stopson your manipulator. Consult your plant or cell documentation to see how yourmanipulator system is configured.


1 Safety1.2.5.1 What is an emergency stop?

Continued

1.3 Safety related instructions

1.3.1 Safety signals in the manual

Introduction to safety signalsThis section specifies all dangers that can arise when doing the work describedin this manual. Each danger 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 operator/service personnel donot eliminate the danger.

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

Danger levelsThe table below defines the captions specifying the danger levels used throughoutthis manual.

SignificanceDesignationSymbol

Warns that an accident will occur if the instructionsare not followed, resulting in a serious or fatal injuryand/or severe damage to the product. It applies towarnings that apply to danger with, for example,contact with high voltage electrical units, explosionor fire risk, risk of poisonous gases, risk of crushing,impact, fall from height, and so on.

DANGER

xx0200000022

Warns that an accident may occur if the instructionsare not followed that can lead to serious injury, pos-sibly fatal, and/or great damage to the product. Itapplies to warnings that apply to danger with, forexample, contact with high voltage electrical units,explosion or fire risk, risk of poisonous gases, riskof crushing, impact, fall from height, etc.

WARNING

xx0100000002

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

ELECTRICALSHOCK

xx0200000024

Warns that an accident may occur if the instructionsare not followed that can result in injury and/ordamage to the product. It also applies to warningsof risks that include burns, eye injury, skin injury,hearing damage, crushing or slipping, tripping, im-pact, fall from height, etc. Furthermore, it applies towarnings that include function requirements whenfitting and removing equipment where there is a riskof damaging the product or causing a breakdown.

CAUTION

xx0100000003

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

ELECTROSTATICDISCHARGE (ESD)

xx0200000023



1 Safety1.3.1 Safety signals in the manual

SignificanceDesignationSymbol

Describes important facts and conditions.NOTE

xx0100000004

Describes where to find additional information orhow to do an operation in an easier way.

TIP

xx0100000098


1 Safety1.3.1 Safety signals in the manual

Continued

1.3.2 Safety symbols on manipulator labels

Introduction to labelsThis section describes safety symbols used on labels (stickers) on the manipulator.Symbols are used in combinations on the labels, describing each specific warning.The descriptions in this section are generic, the labels can contain additionalinformation such as values.

Note

The safety and health symbols on the labels on the manipulator must be observed.Additional safety information given by the system builder or integrator must alsobe observed.

Types of labelsBoth the manipulator and the controller are marked with several safety andinformation labels, containing important information about the product. Theinformation is useful for all personnel handling the manipulator system, for exampleduring installation, service, or operation.The safety labels are language independent, they only use graphics. See Symbolson safety labels on page 40.The information labels can contain information in text (English, German, andFrench).

Symbols on safety labels

DescriptionSymbol

Warning!

xx0900000812

Warns that an accident may occur if the instructions are notfollowed that can lead to serious injury, possibly fatal, and/orgreat damage to the product. It applies to warnings that applyto danger with, for example, contact with high voltage electricalunits, explosion or fire risk, risk of poisonous gases, risk ofcrushing, impact, fall from height, etc.

Caution!

xx0900000811

Warns that an accident may occur if the instructions are notfollowed that can result in injury and/or damage to the product.It also applies to warnings of risks that include burns, eye injury,skin injury, hearing damage, crushing or slipping, tripping, im-pact, fall from height, etc. Furthermore, it applies to warningsthat include function requirements when fitting and removingequipment where there is a risk of damaging the product orcausing a breakdown.

Prohibition

xx0900000839

Used in combinations with other symbols.



1 Safety1.3.2 Safety symbols on manipulator labels

DescriptionSymbol

See user documentation

xx0900000813

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 dismantling see product manual

xx0900000816

Do not dismantle

xx0900000815

Dismantling this part can cause injury.

Extended rotation

xx0900000814

This axis has extended rotation (working area) compared tostandard.

Brake release

xx0900000808

Pressing this button will release the brakes. This means thatthe manipulator arm can fall down.

Tip risk when loosening bolts

xx0900000810

The manipulator can tip over if the bolts are not securelyfastened.




Continued

DescriptionSymbol

Crush

xx0900000817

Risk of crush injuries.

Heat

xx0900000818

Risk of heat that can cause burns.

Moving robot

xx0900000819

The robot can move unexpectedly.

xx1000001141

Brake release buttons

xx0900000820

xx1000001140




Continued

DescriptionSymbol

Lifting bolt

xx0900000821

Chain sling with shortener

xx1000001242

Lifting of robot

xx0900000822

Oil

xx0900000823

Can be used in combination with prohibition if oil is not allowed.

Mechanical stop

xx0900000824

No mechanical stop

xx1000001144

Stored energy

xx0900000825

Warns that this part contains stored energy.Used in combination with Do not dismantle symbol.




Continued

DescriptionSymbol

Pressure

xx0900000826

Warns that this part is pressurized. Usually contains additionaltext with the pressure level.

Shut off with handle

xx0900000827

Use the power switch on the controller.



Continued

1.3.3 DANGER - Moving manipulators are potentially lethal!

DescriptionAny moving manipulator is a potentially lethal machine.When running, the manipulator may perform unexpected and sometimes irrationalmovements. Moreover, all movements are performed with great force and mayseriously injure any personnel and/or damage any piece of equipment locatedwithin the working range of the manipulator.

Elimination

NoteAction

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

Before attempting to run the manipulator,make sure all emergency stop equipmentis correctly installed and connected.

1

How to use the hold-to-run function is de-scribed in section How to use the hold-to-run function in theOperatingmanual - IRC5with FlexPendant.

Usually the hold-to-run function is activeonly in manual full speed mode. To in-crease safety it is also possible to activatehold-to-run for manual reduced speed witha system parameter.

2

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

Make sure no personnel are present withinthe working range of the manipulator be-fore pressing the start button.

3


1 Safety1.3.3 DANGER - Moving manipulators are potentially lethal!

1.3.4 DANGER - First test run may cause injury or damage!

DescriptionSince performing a service activity often requires disassembly of the robot, thereare several safety risks to take into consideration before the first test run.

EliminationFollow the procedure below when performing the first test run after a serviceactivity, such as repair, installation, or maintenance.

Action

Remove all service tools and foreign objects from the robot and its working area1

Check that the fixture and workpiece are well secured, if applicable2

Install all safety equipment properly3

Make sure all personnel are standing at a safe distance from the robot, that is out ofits reach behind safety fences, and so on

4

Pay special attention to the function of the part previously serviced5

Collision risks

CAUTION

When programming the movements of the manipulator always check potentialcollision risks before the first test run.


1 Safety1.3.4 DANGER - First test run may cause injury or damage!

1.3.5 DANGER - Make sure that the main power has been switched off!

DescriptionWorking with high voltage is potentially lethal. Persons subjected to high voltagemay suffer cardiac arrest, burn injuries, or other severe injuries. To avoid thesedangers, do not proceed working before eliminating the danger as detailed below.

Elimination, Panel Mounted Controller

Note/illustrationAction

xx0600003255

Switch off the main switch for the controller.1

Elimination, Single Cabinet Controller


xx0600002782

Switch off the main switch on the controllercabinet.

1

A: Main switch



1 Safety1.3.5 DANGER - Make sure that the main power has been switched off!

Elimination, Dual Cabinet Controller


xx0600002783

Switch off the main switch on the DriveModule.

1

K: Main switch, Drive Module

A: Main switch, Control ModuleSwitch off the main switch on the ControlModule.

2


1 Safety1.3.5 DANGER - Make sure that the main power has been switched off!

Continued

1.3.6 WARNING - The unit is sensitive to ESD!

DescriptionESD (electrostatic discharge) is the transfer of electrical static charge between twobodies at different potentials, either through direct contact or through an inducedelectrical field. When handling parts or their containers, personnel not groundedmay potentially transfer high static charges. This discharge may destroy sensitiveelectronics.

Elimination

NoteAction

Wrist straps must be tested frequently to ensurethat they are not damaged and are operating cor-rectly.

Use a wrist strap1

The mat must be grounded through a current-limit-ing resistor.

Use an ESD protective floor mat.2

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

Use a dissipative table mat.3

Location of wrist strap buttonThe location of the wrist strap button is shown in the following illustration.

IRC5The wrist strap button is located in the top right corner.

xx0500002171

Wrist strap buttonA



1 Safety1.3.6 WARNING - The unit is sensitive to ESD!

Panel Mounted Controller

xx0600003249

Panel Mounted Control ModuleA

Panel Mounted Drive ModuleB

Wrist strap button NOTE! When not used, the wrist strap must always be attachedto the wrist strap button.

C


1 Safety1.3.6 WARNING - The unit is sensitive to ESD!

Continued

1.3.7 WARNING - Safety risks during handling of batteries

DescriptionUnder normal conditions of use, the electrode materials and liquid electrolyte inthe batteries are not exposed to the outside, provided the battery integrity ismaintained 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 batterycontainer. Electrolyte leakage, electrode materials reaction with moisture/water orbattery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Elimination

NoteAction

Operating temperaturesare listed in Pre-install-ation procedure onpage 59.

Do not short circuit, recharge, puncture, incinerate, crush,immerse, force discharge or expose to temperatures abovethe declared operating temperature range of the product.Risk of fire or explosion.

1

Use safety glasses when handling the batteries.2

In the event of leakage, wear gloves and chemical apron.3

In the event of fire, use self-contained breathing apparatus.4


1 Safety1.3.7 WARNING - Safety risks during handling of batteries

1.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

DescriptionWhen handling gearbox lubricants, there is a risk of both personal injury andproduct damage occurring. The following safety information must be regardedbefore performing any work with lubricants in the gearboxes.

Note

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

Note

When aggressive media is handled, an appropriate skin protection must beprovided.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Warnings and elimination

Elimination/ActionDescriptionWarning

Make sure that protective gearlike goggles and gloves are al-ways worn during this activity.

Changing and draining gearboxoil or grease may require hand-ling hot lubricant heated up to90 °C.

xx0100000002

Hot oil or grease

Make sure that protective gearlike goggles and gloves are al-ways worn.

When working with gearbox lub-ricant there is a risk of an allergicreaction.

xx0100000002

Allergic reaction

Open the plug carefully and keepaway from the opening. Do notoverfill the gearbox when filling.

When opening the oil or greaseplug, there may be pressurepresent in the gearbox, causinglubricant to spray from theopening.xx0100000002

Possible pressurebuild-up in gearbox



1 Safety1.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Elimination/ActionDescriptionWarning

Make sure not to overfill thegearbox when filling it with oil orgrease!

Overfilling of gearbox lubricantcan lead to internal over-pres-sure inside the gearbox which inturn may:

• damage seals and gas-kets

• completely press outseals and gaskets

• prevent the robot frommoving freely.

xx0100000002

Do not overfill

After filling, check the correctlevel.

When filling gearbox oil, do notmix different types of oil unlessspecified in the instructions. Al-ways use the type of oil specifiedby the manufacturer!

Mixing types of oil may causesevere damage to the gearbox.

xx0100000002

Do not mix types of oil

When changing gearbox oil, firstrun the robot for a time to heatup the oil.

Warm oil drains quicker thancold oil.

xx0100000098

Heat up the oil

After refilling, check the lubricantlevel.

The specified amount of oil orgrease is based on the totalvolume of the gearbox. Whenchanging the lubricant, theamount refilled may differ fromthe specified amount, dependingon how much has previouslybeen drained from the gearbox.

xx0100000004

Specified amount de-pends on drainedvolume


1 Safety1.3.8 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Continued

2 Installation and commissioning2.1 Introduction

GeneralThis chapter contains information for installing the IRB 4400 at the working site.More detailed technical data can be found in the Product specification for the IRB4400, such as:

• Load diagram• Permitted extra loads (equipment)• Location of extra loads (equipment).

Safety informationBefore any installation work is commenced, it is extremely important that all safetyinformation is observed!There are general safety aspects that must be read through, as well as more specificsafety information that describes the danger and safety risks when performing theprocedures. Read the chapterSafety on page17 before performing any installationwork.

Note

If the IRB 4400 is connected to power, always make sure that the robot isconnected to protective earth before starting any installation work!For more information see:

• Product manual - IRC5• Product manual - IRC5 Panel Mounted Controller


2 Installation and commissioning2.1 Introduction

2.2 Installation and operational requirements for Foundry Prime robots

IntroductionRobots with protection type Foundry Prime are specially designed to work in harshenvironments. To ensure that the protection offers the best reliability, specialmeasures are required during installation and operation. It is required that theenvironmental and application conditions are fulfilled and that the specialmaintenance activities and intervals for the Foundry Prime protected robot arefollowed.

Fluids in the vicinity of the robotIf fluids that can cause rust formation, for example, water etc., are used in thevicinity of the robot it is required to add rust inhibator to the fluid or take othermeasures to prevent rust on unpainted joints or other unprotected surfaces of therobot.

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

Pressurized componentsThe motors, the balancing device, and the serial measurement board cavity mustbe pressurized on Foundry Prime robots during operation and shut down. Theoverpressure can be dropped when atmospheric humidity has reached the samelevel as the surrounding environment.At the installation of the Foundry Prime robot a pressure sensor and pressure reliefvalve (not included) must be installed in the air supply system to monitor the supplyof air pressure in order to secure a correct pressure.The overpressuremust be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independentof Motors On/Off mode, start-up, and shut down periods.

WARNING

If the air pressure exceeds the specified, it could result in a brake failure in themotors and cause the robot arms to fall down, leading to personal injury orphysical damage.

WARNING

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

Note

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



2 Installation and commissioning2.2 Installation and operational requirements for Foundry Prime robots

Air quality for pressurizing of robotThe air must be dry and clean, such as instrument air. The following table describesthe air specifications.

ValueParameter

<+2°C at 6 barDew point

<5 micronsSolid particle size

<1 ppm (1 mg/m3 )Oil content

Precautionary measures

Note

It is strictly forbidden to expose any part of the robot to direct high pressure waterjet! The sealing joints between the moving parts on the wrist must not be exposedto high pressure water.Rebounding high pressure water jet must be avoided. ABB recommends usinga tool design with integrated covers that protect the wrist from direct or indirecthigh pressure water jet.

Note

Make sure that the special Foundry Prime painting of the robot is not brokenduring testing, installation, or repair work. Use the touch up kit available forFoundry Prime (article number 3HAC035355-001) to repair any damages in thepaint.




Continued

Sensitive points IRB 4400Illustration shows points that are particularly sensitive to water spray.

C

B

A

xx0800000462

Inside lower armA

Cable packageB

WristC

Shut-down periodsDuring shut-down periods the cleaning cell must be ventilated out (aired out). Thisreduces the risk that moister is sucked into gearboxes during cooling down. Itgives the robot the possibility to dry as the rust inhibation effect normally getsreduced after some time.Ventilate and air out the cell during and after shut-downs:

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

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

• Will give the robot a chance to dry as most rust preventive components inwashing detergents have a decaying effect, i.e. the rust preventive effect isreduced after a time. Please refer to the Product Specification of the washingdetergent in question for decaying effect. Washing detergent or water withoutrust inhibator can give an accelarated corrosion on some robot components.

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



Continued

2.3 Unpacking

2.3.1 Pre-installation procedure

IntroductionThis section is intended for use when unpacking and installing the robot for thefirst time. It also contains information useful during later re-installation of the robot.

Checking the pre-requisites for installationInstallation craftsmen working with an ABB robot must:

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

• conform to all national and local codes.

Action

Visually inspect the robot to make sure that it is not damaged.1

Make sure that the lifting accessory used is suitable to handle the weight of the robotas specified in:

• Weight, robot on page 59

2

If the robot is not installed directly, it must be stored as described in:• Storage conditions, robot on page 61

3

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

• Operating conditions, robot on page 61

4

Before taking the robot to its installation site, make sure that the site conforms to:• Loads on foundation, robot on page 60• Protection classes, robot on page 61• Requirements, foundation on page 61

5

Before moving the robot, please observe the stability of the robot:• Risk of tipping/stability on page 88

6

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

• On-site installation on page 63

7

Install required equipment, if any.8

Weight, robotThe table shows the weight of the robot.

WeightRobot model

1300 kgIRB 4400

Note

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



2 Installation and commissioning2.3.1 Pre-installation procedure

Loads on foundation, robotThe illustration shows the directions of the robots stress forces. The directions arevalid for all floor mounted and suspended robots.

xy

xy

z

z

T

F

F

T

xx1100000521

Force in any direction in the XY planeFxy

Force in the Z planeFz

Bending torque in any direction in the XY planeTxy

Bending torque in the Z planeTz

The table shows the various forces and torques working on the robot during differentkinds of operation.

Note

These forces and torques are extreme values that are rarely encountered duringoperation. The values also never reach their maximum at the same time!

Floor mounted

Max. load (emergency stop)Endurance load (in operation)Force

± 9000 N± 7500 NForce xy

+9500 ± 3000 N+9500 ± 2000 NForce z

± 16000 Nm± 14000 NmTorque xy

± 4000 Nm± 2000 NmTorque z




Continued

Requirements, foundationThe table shows the requirements for the foundation where the weight of theinstalled robot is included:

NoteValueRequirement

Flat foundations give better repeatability of theresolver calibration compared to original settingson delivery from ABB.

0.5Maximum deviationfrom levelness

The value for levelness aims at the circumstanceof the anchoring points in the robot base.In order to compensate for an uneven surface,the robot can be recalibrated during installation.If resolver calibration is changed this will influ-ence the absolute accuracy.

The limit for the maximum payload on the robotis reduced if the robot is tilted from 0°.

-Maximum tilt

Contact ABB for further information about accept-able loads.

-Minimum resonancefrequency

Storage conditions, robotThe table shows the allowed storage conditions for the robot:

ValueParameter

-25° CMinimum ambient temperature

+55° CMaximum ambient temperature

+70° CMaximum ambient temperature (less than 24 hrs)

95% at constant temperature(gaseous only)

Maximum ambient humidity

Operating conditions, robotThe table shows the allowed operating conditions for the robot:

ValueParameter

+5° CMinimum ambient temperature

+45° CMaximum ambient temperature

95% at constant temperatureMaximum ambient humidity

Protection classes, robotThe table shows the protection class of the robot:

Protection classEquipment

IP54Manipulator, protection type Standard

IP67, steam washableManipulator, protection type Foundry Prime



Continued

2.3.2 Working range, IRB 4400

Extreme positionsThe illustration below shows the extreme positions of the robot arms IRB 4400:

xx0300000241

Angle Axis 3 (de-grees)

Angle Axis 2 (de-grees)

Position Z (mm)Position X (mm)Pos no.

00172010800

-30021408871

6508367082

-609522118943

4095-1265704

40-701554515

65-7012102276

Robot motionThe table below specifies the types and ranges of the robot motion in every axis.

Range of movementType of motionLocation of motion

+165° to -165°Rotation motionAxis 1

+95° to -70°Arm motionAxis 2

+65° to -60°Arm motionAxis 3

+200° to -200°Wrist motionAxis 4

+120° to -120°Bend motionAxis 5

+400° to -400°Turn motionAxis 6


2 Installation and commissioning2.3.2 Working range, IRB 4400

2.4 On-site installation

2.4.1 Lifting robot with roundslings

GeneralLift the robot using lifting straps and a traverse crane according to this section.

Required equipment

NoteArt. no.Equipment

Lifting capacity: 2100kg (max. load at 90°)Crane

Lifting capacity/sling: 1100kgRound slings, 2 m2 pcs for IRB 4400

Type: OBK 7-8Lifting lugs

CAUTION

The IRB 4400 robot weighs 1300 kg.All lifting accessories used must be sized accordingly!

WARNING

Personnel must not, under any circumstances, be present under the suspendedload!

CAUTION

Failure to attach the straps correctly can cause the suspended load to tilt suddenlyand cause both personal injury and severe damage to the load.



2 Installation and commissioning2.4.1 Lifting robot with roundslings

Lifting, robot version, IRB 4400The lifting equipment is attached to the robot as shown in the figure below.

0°

xx0300000245

Lifting instruction, IRB 4400The procedure below details how to lift the complete robot.

InfoAction

Detailed in sectionManually releasing thebrakes on page 66.

Release the brakes manually, to make itpossible to alter the positions of the arms.

1

Move the robot to the calibration position.2




Continued

InfoAction

0°

xx0300000245

Move the lower arm backwards to get bal-ance, according to angle specified to theright.

3

Shown in the figure Lifting, robot version,IRB 4400 on page 64.

Attach the round slings to the special eyebolts on the gearbox unit for axes 2 and 3using lifting lugs.

4

The roundsling and lifting lug dimensionsmust comply with the applicable stand-ards specified in Required equipment onpage 63.

Lift the robot to its installation site.5Make sure the slings do not rub against anysharp edges!



Continued

2.4.2 Manually releasing the brakes

GeneralThe 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 properlyattached!

DANGER

When releasing the holding brakes, the robot axes may move very quickly andsometimes 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 controllerThe procedure details how to release the holding brakes with push-buttons, whenthe robot is connected to the controller.

NoteAction

xx0300000198

The internal brake release unit is locatedat the base of the robot.

1

The brake release unit is equipped withsix buttons for controlling the axes brakes.The buttons are numbered according tothe numbers of the axes.

2



2 Installation and commissioning2.4.2 Manually releasing the brakes

NoteAction

Release the holding brake on a particularaxis by pressing the corresponding buttonon the push-button unit and keeping itdepressed.

3

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

4

Using the push-button on the robot with an external power supplyThe procedure below details how to release the holding brakes with thepush-buttons, when the robot is not connected to the controller.

NoteAction

xx0300000200

Connect an external 24VDC power supply tothe connector R1.MP on the robot base, asshown in the figure to the right.Note! Be careful not to interchange the 24Vand 0V pins.If they are mixed up, damage can be causedto the brake release unit and the systemboard.

xx0200000022

DANGER!Incorrect connections can cause all brakesto be released simultaneously!

1

Connect to connector R1.MP:• 0V: pin B14 or B15• +24V: pin B16

The brake release unit is equipped withsix buttons for controlling the axesbrakes. The buttons are numbered accord-ing to the numbers of the axes.

Release the holding brake on a particularaxis by pressing the corresponding buttonon the push-button unit and keeping it de-pressed.

2

See the previous figure.

The brake will function again as soon as thebutton is released.

3




Continued

Using an external voltage supply directly on the respective brakeThe procedure below details how to release the holding brake of a specific axis bysupplying external voltage directly on the brake.

NoteAction

Make the connection to the current motoraccording to the Circuit Diagram.

Every axis has a holding brake built into theaxis motor. This holding brake may be re-leased by connecting 24VDC power supplydirectly to one of the connectors in the motor.

DANGER

When power is connected directly to thebrake cable, the brake will be released imme-diately when the power is switched on.This may cause some unexpected robotmovements!

1

See chapterCircuit diagram on page301.



Continued

2.4.3 Orienting and securing the robot

GeneralThis section details how to orient and secure the robot to the base plate after fittingit to the foundation.

Securing parts/factsThe table below specifies the type of securing screws and washers to be used tosecure the robot to the base plate/foundation.

Amount/NoteDimension/art. no.Securing parts/fact

3 pcsM20Securing screws, oiled

3 pcsThickness: 3 mmWashersOuter diameter: 36 mmInner diameter: 21 mm

2 pcs21510024-169Guide sleevesAdded to the rear bolt holes,to allow the same robot to bere-mounted without programadjustments.

Oiled screws350 - 400 NmTightening torque

xx0300000251

Level surface requirements



2 Installation and commissioning2.4.3 Orienting and securing the robot

Hole configuration and dimensionsThe illustration below shows the hole configuration and hole dimensions of therobot base, seen from below.The cut x-x shows the dimension of the rear bolt holes, where the guide sleevesmay be used.

xx0300000252

Rear bolt holesA

Center line, axis 1B

Orienting and securing the robotThe procedure below details how to orient and secure the robot to the base plateafter fitting the plate to the foundation.

Info/IllustrationAction

WARNING

When the robot is put down, before attach-ment to the floor is done, the risk of tippingis big, if not properly secured.

1

CAUTION

The IRB 4400 robot weighs 1300 kg.All lifting accessories used must be sizedaccordingly!

2

Detailed in section Lifting robot withroundslings on page 63.

Lift the robot.3

Move the robot to the vicinity of the installa-tion site.

4




Continued


Art. no. is specified inSecuring parts/factson page 69.

Fit two guide sleeves to the rear bolt holesin the base.

5

Shown in the figure Hole configurationand dimensions on page 70.

Guide the robot gently using M20 screwswhile lowering it into its mounting position.

6

Specified in Securing parts/facts onpage 69.

Fit the securing screws and washers in thebase attachment holes.

7

Attachment holes shown in the figureHole configuration and dimensions onpage 70.

When bolting a mounting plate or frame to aconcrete floor, follow the general instructionsfor expansion-shell bolts.

8

The screw joint must be able to withstand thestress loads defined in section Loads onfoundation, robot on page 60.



Continued

2.4.4 Fitting equipment on robot

GeneralThe robot features mounting holes for additional equipment.Access to any of the following mounting holes may be obstructed by any additionalcabling, equipment etc. fitted by the robot user. Make sure the required mountingholes are accessible when planning the robot cell.Never drill a hole in the robot without first consulting ABB!

Fitting equipment on upper arm, IRB 4400The illustration below shows the mounting holes available for fitting extra equipmenton the upper arm for robot versions IRB 4400.The shaded area indicates the permitted positions (center of gravity) for any extraequipment mounted in the holes.

xx0300000264

Max. 15 kgE

M8 (2x), holes used if option 043 is chosen. Depth of thread: 9 mmF

M8 (3x) Depth of thread: 14 mmG

571 mm for IRB 4400.H

Max. 5 kg for IRB 4400 at max. handling weightI

M6 (2x), tapped depth 12 mmK



2 Installation and commissioning2.4.4 Fitting equipment on robot

Fitting equipment on gearbox unit, IRB 4400The illustration below shows the mounting holes available for fitting extra equipmenton the gearbox unit.The shaded area indicates the permitted positions (center of gravity) for any extraequipment mounted in the holes.

xx0300000266

M8 (3x), R=2. Depth 16 mm (if option 623 is chosen, these holes are occupied)A

Max. 35 kg for IRB 4400B




Continued

Fitting equipment on mounting flange, IRB 4400The illustration below shows the mechanical interface for the mounting flange,robot version IRB 4400.

xx0300000267



Continued

2.4.5 Loads

GeneralAny loads mounted on the robot must be defined correctly and carefully (withregard to the position of center of gravity and mass moments of inertia) in orderto avoid jolting movements and overloading motors, gears and structure.

CAUTION

Incorrectly defined loads may result in operational stops or major damage to therobot.

ReferencesLoad diagrams, permitted extra loads (equipment) and their positions are specifiedin the product specification. The loads must also be defined in the software asdetailed in:

• User’s guide - S4Cplus (BaseWare OS 4.0) , (M2000, M2000A)• Operating manual - IRC5 with FlexPendant (M2004)

Stop time and braking distancesRobot motor brake performance depends on any loads attached. For informationabout brake performance, read the product specification for the robot.


2 Installation and commissioning2.4.5 Loads

2.4.6 Installation of signal lamp (option)

Signal lampSee the assembly instruction delivered with the signal lamp.


2 Installation and commissioning2.4.6 Installation of signal lamp (option)

2.5 Restricting the working range

2.5.1 Introduction

GeneralWhen installing the robot, make sure that it can move freely within its entire workingspace. If there is a risk that it may collide with other objects, its working spaceshould be limited.The working range of the following axes may be restricted:

• Axis 1, hardware (mechanical stop) and software (signal from adjustableposition switch)

• Axis 2, hardware (mechanical stop)• Axis 3, software (signal from limit switch)

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

Note

Adjustments must also be made in the robot configuration software (systemparameters). References to relevant manuals are included in the installationprocedures.


2 Installation and commissioning2.5.1 Introduction

2.5.2 Mechanically restricting the working range of axis 1

Mechanically restricting the working rangeThe working range of axis 1 can be restricted mechanically by fitting additionalmechanical stops to the base, as detailed in this section.

Required equipment

NoteArt. no.Equipment, etc.

Includes 2 additional stop lugs, 8 attachmentscrews, 8 plain washers and a label

3HAB3833-1Mechanical stop, axis 1

4 pcs/lug, included in 3HAB3833-19ADA183-71Attachment screwM12x60

4 pcs/lug, included in 3HAB3833-19ADA312-9Washer13x24x2.5

Content is defined in section Standard toolson page 277.

3HAC17594-1Standard toolkit

These procedures include references to thetools required.

Other tools and proceduresmay be required. See refer-ences to these proceduresin the step-by-step instruc-tions below.



2 Installation and commissioning2.5.2 Mechanically restricting the working range of axis 1

Additional stopsThe additional stops are fitted as shown in the figure.

xx0300000258

Mechanical stop lugsB

Attachment screw and washerC

Max. working range with stop lugs (250°)D

Stop pinE

Min. working range with stop lugs (127°)F

Fitting, mechanical stop axis 1How to fit the additional mechanical stop to the base is described in the procedure.Mounting instructions are also supplied with the kit.

NoteAction

See the figure Additional stops onpage 79 for guidance.

Determine the position of the stop lugs andmark the hole positions on the base.

1

Drill Ø10.2 mm to a maximum depth of 45mm and tap with M12 thread. Min. threaddepth 35 mm.

2




Continued

NoteAction

Specified in Required equipment onpage 78.

Fit the stop lugs firmly with attachmentscrews and washers according to the figureAdditional stops on page 79.

3

M12x60, tightening torque: 82 Nm, oillubrication.



Continued

2.5.3 Mechanically restricting the working range of axis 2

Mechanically restricting the working rangeThe working range of axis 2 can be restricted mechanically by fitting additionalmechanical stops (spacers and dampers) to the lower arm and gearbox unit axis1-3, as detailed in this section. Note that the system parameter configuration mustalso be adjusted (Upper joint bound and Lower joint bound for the type Arm in thetopic Motion).

Required equipment

NoteArt. no.Spare part no.Equipment, etc.

Includes spacers, dampers,attachment screws and nuts.

3HAC4225-1Mechanical stop, axis 2

3HAB9185-1Spacer (damper)

3HAC3962-1Spacer

Content is defined in sectionContents, standard toolkit onpage 277.


These procedures includereferences to the tools re-quired.





Additional stopsThe additional mechanical stops (spacers and dampers) are fitted to the lower armand the gearbox unit, as shown in the figure below.

xx0300000260

View A of the lower armA

View B of the lower armB

Cut of the mech stop attachmentC

SpacerD

Attachment screw, spacer (+nut)E

DamperF

Attachment screw, damper (+nut)G




Continued

Working rangeThe working range of axis 2 can be restricted according to the table below.

Spacer, qtyDamper, qtyWorking range

--+95° / -70°

2-+95° / -40°

22+95° / -10°

-2+65° / -70°

22+65° / -40°

24+65° / -10°

-4+35° / -70°

24+35° / -40°

26+35° / -10°

-6+5° / -70°

26+5° / -40°

28+5° / -10°

• Each damper is fitted with: 2 attachment screws and 2 hexagon nuts.• Each spacer is fitted with: 1 attachment screw and 1 hexagon nut.

Fitting, mechancial stop axis 2The procedure below details how to fit the additional mechanical stop to the lowerarm and the gearbox unit.Mounting instructions are also supplied with the kit.


See Working range on page 83.Determine the working range restriction.1

Shown in the figure Additional stops onpage 82.

Fit both the spacers to either side of thegearbox unit, with the attachment screws andnuts, spacer.

2

Art. no. is specified in Required equip-ment on page 81.Attachment screw: 1 pc/spacer, M16x70.Tightening torque: 156 Nm.

Shown in the figure Additional stops onpage 82.

Fit the dampers to both sides of the lowerarm with the attachment screws and nuts,damper.

3

Art. no. is specified in Required equip-ment on page 81.Attachment screws: 2 pcs/damper,M10x60. Tightening torque: 49 Nm.



Continued

2.5.4 Electrically restricting the working range of axis 3

Electrically restricting the working rangeThe working range of axis 3 can be limited by fitting an electric switch on thegearbox for axis 3, which senses the current position via a cam. The systemparameter configuration must also be updated.

Electrical stopAll the separate parts of the electrical stop are fitted to axis 3 as shown in the figurebelow.

xx0300000262

Sealing with dust lip (3HAB 3701-14)A

Stud (2122 2012-867)B

All screws are locked with locking liquidC

Tap (3HAB 3798-1)D

Hexagon nut (9ADA 267-7)E

Disc (3HAB 3799-1)F

Screw (9ADA 618-44)G

Cam (3HAB 3800-1)H

Bracket (3HAB 8400-1)I

Limit switch complete (3HAB 8312-1)J

Screw (9ADA 629-50)K

Attachment screw (9ADA 183-35)L

Retaining ring (9ABA 135-18), reducing coupling (2686 015-3), washer (2152398-3)

M



2 Installation and commissioning2.5.4 Electrically restricting the working range of axis 3

Required equipment


Includes all spare parts shown in thefigure Electrical stop on page 84.

3HAB3795-1Electrical stop, axis 3

Loctite 243Locking liquid

Content is defined in sectionContents,standard toolkit on page 277.


These procedures include referencesto the tools required.

Other tools and procedures maybe required. See references tothese procedures in the step-by-step instructions below.

See chapter Circuit diagram onpage 301.

Circuit diagrams

Fitting, electrical stop axis 3The procedure below details how to fit the electrical stop to axis 3.Mounting instructions are also supplied with the kit.


xx0300000263

Remove the covers (A) from axis 3.1


All screws are locked with locking liquid,when fitted.

2

Fit the electrical stop according to the figureElectrical stop on page 84.

3

The system parameters that must bechanged (Upper joint bound and Lowerjoint bound) are described in Technicalreference manual - System parameters.

Adjust the software working range limitations(system parameter configuration) to corres-pond to the mechanical limitations.

4


2 Installation and commissioning2.5.4 Electrically restricting the working range of axis 3

Continued

2.5.5 Unlimited working range

Resetting the work area for an axisThe function Resetting the work area for an axis, included in Advanced Motions3.0, can also be used for axis 4. To enable this function, the mechanical stop onaxis 4 should be removed. Follow the procedure below to dismantle the mechanicalstop.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

Location of mechanical stop, axis 4The mechanical stop of axis 4 is located as shown in the figure below.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000176

Mechanical stop axis 4A

Damper axis 4B

Attachment screws, mechanical stopC



2 Installation and commissioning2.5.5 Unlimited working range

Removal of mechanical stop, axis 4The procedure below details how to remove the mechanical stop of axis 4, to enablethe function Resetting the work area for an axis.

WARNING

When the damper is removed from axis 4, the axis does not have a mechanicalstop! If the robot is provided with cabling on the upper arm, the cabling can bedamaged when the function Resetting the work area for an axis is used, or if therobot is jogged uncalibrated.


DANGER

Turn off all:• electric power supply• hydraulic pressure supply• air pressure supply (do not turn off for

Foundry Prime robots!)to the robot, before entering the robot work-ing area.

1

Shown in the figure Location of mechan-ical stop, axis 4 on page 86.

Loosen the attachment screws, mech stopand remove the mechanical stop, axis 4.

2

Slowly rotate axis 4 until the damper is visiblethrough the hole.

3

Remove the damper.4

4 pcs, M8x16. Tightening torque: 24 Nm.Refit the mechanical stop to the axis 4 withits attachment screws.

5


2 Installation and commissioning2.5.5 Unlimited working range

Continued

2.5.6 Risk of tipping/stability

Risk of tippingIf the robot is not fastened to the foundation and standing still, the robot is notstable in the whole working area. Moving the arms 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 transport positionThis figure shows the robot in its shipping position, which also is a recommendedtransport position.

0°

xx0300000245

WARNING

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


2 Installation and commissioning2.5.6 Risk of tipping/stability

2.6 Electrical connections

2.6.1 Customer connection on robot

Location of customer connectionFor the connection of extra equipment to the robot, cables and air hose areintegrated into the robot´s cabling, and there is one FCI UT071823SH44N and oneFCI UT071412SH44N connector on the rear part of the upper arm.The customer connections are located on the robot as shown in the figure.

xx0300000270

R1.CP, R1.CS, Air R1/4"A

R2.CP, R2.CS, Air R1/4"B

R3.CP, R3.CS, Air R1/4"C

Extra equipment connectionsConnections to the:

• air hose (R1/4" ) is located on the rear part of the upper arm and at the base.Max. 8 bar. Inner hose diameter: 8 mm.

• signal cabling (option) is located on the front of the upper arm.Number of signals: 23 (50V, 250mA), 10 (250V, 2A), one protective ground.

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

ContentArt. no.ConnectorConnectionset

• socket for area of 0.14 - 0.5 mm2

• compression gland for cables,diameter 2 x 12 mm

• key pin

3HAC12275-1R1.CP/CSR1.CP/CS(protectionStandard)



2 Installation and commissioning2.6.1 Customer connection on robot

ContentArt. no.ConnectorConnectionset

• socket for area of 0.14 - 0.5 mm2

• compression gland for cables,diameters 10 mm and 12 mm

• key pin

3HAC12276-1R1.CP/CSR1.CP/CS F(protectionFoundryPrime)

• pins for cable area of 0.13 - 0.25mm2

• reduction hose, bottled-shaped• reduction hose, angled

3HAC12327-1R2.CS/R3.CSR2.CS/R3.CS

• pins for cable area of 0.13 - 0.25mm2

• reduction hose, bottled-shaped• reduction hose, angled

3HAC12326-1R2.CP/R3.CPR2.CP/R3.CP


2 Installation and commissioning2.6.1 Customer connection on robot

Continued

2.6.2 Customer connections on upper arm

Customer connections on upper armThe figure shows the customer connections on the upper arm, including the optionalsignal lamp that can be fitted to the armhouse.

xx0300000269

R2.CPA

R2.CSB

Signal lamp (option)C

R3.H1 +, R3.H2 -D

Power supply connections on upper arm

Customer Contact on robot base(cable between robot and controllernot supplied)

CustomerContacton Upper arm, R2

Customer Ter-minal Controller

Signal name

RI.CP/CS.A1R2.CP.AXT6.1CPA

RI.CP/CS.B1R2.CP.BXT6.2CPB

RI.CP/CS.C1R2.CP.CXT6.3CPC

RI.CP/CS.D1R2.CP.DXT6.4CPD

RI.CP/CS.A2R2.CP.EXT6.5CPE

RI.CP/CS.B2R2.CP.FXT6.6CPF

RI.CP/CSP EarthR2.CP.G (Earth)



2 Installation and commissioning2.6.2 Customer connections on upper arm




Signal name

R2.CP.H (Key pin)XT6.H

RI.CP/CS.C2R2.CP.JXT6.7CPJ

RI.CP/CS.D2R2.CP.KXT6.8CPK

RI.CP/CS.A3R2.CP.LXT6.9CPL

RI.CP/CS.B3R2.CP.MXT6.10CPM

Signal connections on upper arm




Signal name

R1.CS/CP.B5R2.CS.AXT5.1CSA

R1.CS/CP.C5R2.CS.BXT5.2CSB

R1.CS/CP.D5R2.CS.CXT5.3CSC

R1.CS/CP.A6R2.CS.DXT5.4CSD

R1.CS/CP.B6R2.CS.EXT5.5CSE

R1.CS/CP.C6R2.CS.FXT5.6CSF

R1.CS/CP.D6R2.CS.GXT5.7CSG

R1.CS/CP.A7R2.CS.HXT5.8CSH

R1.CS/CP.B7R2.CS.JXT5.9CSJ

R1.CS/CP.C7R2.CS.KXT5.10CSK

R1.CS/CP.D7R2.CS.LXT5.11CSL

R1.CS/CP.A8R2.CS.MXT5.12CSM

R1.CS/CP.B8R2.CS.NXT5.13CSN

R1.CS/CP.C8R2.CS.PXT5.14CSP

R1.CS/CP.D8R2.CS.RXT5.15CSR

R1.CS/CP.A9R2.CS.SXT5.16CSS

R1.CS/CP.B9R2.CS.TXT5.17CST

R1.CS/CP.C9R2.CS.UXT5.18CSU

R1.CS/CP.D9R2.CS.VXT5.19CSV

R1.CS/CP.A10R2.CS.WXT5.20CSW

R1.CS/CP.B10R2.CS.XXT5.21CSX


2 Installation and commissioning2.6.2 Customer connections on upper arm

Continued

2.7 Additional installation, Foundry Prime

2.7.1 Installation of IRB 4400 in a water jet application

GeneralRobots delivered with the Foundry Prime protection are specially designed to workin water jet cleaning cells with 100% humidity and alkaline detergent. To ensurethat the protection offers the best reliability, some measures are needed duringinstallation of the robot according to the procedures below.

Note

For best reliability, it is also of highest importance that the special maintenanceinstructions 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. gearboxesdue to the raised vacuum when cooled down.

Environmental conditions

100%Humidity

<9.0Washing detergent with pH

Washing detergent must contain rust inhibitor andbe approved by ABB.

<60°C, used in a typical waterjet clean-ing application at suitable speed.

Cleaning bath temperature

Air specification for pressurizing of robotThe air must be dry and clean, such as instrument air. Following table details theair specification.

<+2°C at 6 barDew point

<5 micronsSolid particle size

<1 ppm (1 mg/m3)Oil content

0.2 - 0.3 barPressure to robot

WARNING

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



2 Installation and commissioning2.7.1 Installation of IRB 4400 in a water jet application

WARNING

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

Note

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

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

WARNING

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


xx0600003107

Connect a compressed air hose to air con-nector on robot base, see illustration.

1

• A: connection to motors

Do this when the controller cables areconnected.

Protect the screws on the Harting connectorson the robot base from corrosion with Mer-casol.

2

See Air specification for pressurizing ofrobot on page 93 for correct pressure.

Pressurize the robot.3

See Inspection of air hoses (FoundryPrime) on page 106.

Inspect the air system.4

Protecting from high pressure water

WARNING

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 todirect or rebounding high-pressure jet of water.




Continued

Protecting the wrist jointsThe sealings between the moving parts on the wrist must not be exposed to directhigh-pressure water. We recommend that the gripper include a shield that preventsdirect water flush on the sealing surfaces of the wrist. The sealings are pointedout in the illustration below.

A

B

C

xx0600003108

Axis 5, bearing support sideA

Axis 5, bearing gear sideB

Axis 6, mounting flange - gear houseC

Protecting the wrist flange from corrosionThe mounting surface on the wrist flange is protected with grease. The joint betweenthe wrist flange and the tool and the screw holes on the wrist flange must beprotected.


AB

xx0600003109

After mounting the tool, clean the followingsurfaces from grease:

• the visible surface (not painted)• the rear end of the screw holes and

end of screws.

1

A screw holes and screwsB unpainted surface

Protect these surfaces with Mercasol.2




Continued


Inspection of air hoses (Foundry Prime)on page 106

Before running the robot in a water jetcleaning cell:

• perform a inspection of the pressurein motors and SMB cavity.

3



Continued

2.7.2 Commissioning (Foundry Prime)

GeneralThe following should be taken in consideration when running a robot in a water jetapplication cell:

CAUTION

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

Note

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

Note

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


2 Installation and commissioning2.7.2 Commissioning (Foundry Prime)

3 Maintenance3.1 Introduction

Structure of this chapterThis chapter describes all the maintenance activities recommended for the IRB4400.It is based on the maintenance schedule found at the beginning of the chapter.The schedule contains information about required maintenance activities includingintervals, 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 up according to themaintenance activity.

Safety informationObserve all safety information before conducting any service work!There are general safety aspects that must be read through, as well as more specificsafety information that describes the danger and safety risks when performing theprocedures. Read the chapter Safety on page 17 before performing any servicework!

Note

If the IRB 4400 is connected to power, always make sure that the IRB 4400 isconnected to protective earth before starting any maintenance work!For more information see:



3 Maintenance3.1 Introduction

3.2 Introduction for Foundry Prime robots

IntroductionThe Foundry Prime robots are designed for installation and operation in very hardenvironments. 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 wheninstalling, cleaning, maintaining, and repairing ABB Foundry Prime robots.An extended maintenance program including service activities and schedule isrequired.Cleaning and maintenance of robots with Foundry Prime protection shall beperformed by trained personnel.

Specific maintenance activities and intervals for Foundry PrimeThe Foundry Prime robots have specific maintenance activities and intervalscompared to standard robots:

• More comprehensive• More frequent• Sample activities for check of lubrication• Conditional - for example, water content in gearbox control/decide

replacement intervalsPreventive measures every 6 months secure the uptime of the robot:

• Inspection of oil level in gearboxes• Surface treatment• Cable harness• Balancing device

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

Non-predictable situationsNon-predictable situations can give rise to inspections of the robot. Any damagesmust be attended to immediatly!

Note

Repair damages on painted surfaces as soon as possible. Use the touch-up kit3HAC035355-001 for Foundry Prime protection.

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


3 Maintenance3.2 Introduction for Foundry Prime robots

3.3 Maintenance schedule

3.3.1 Specification of maintenance intervals

IntroductionThe intervals are specified in different ways depending on the type of maintenanceactivity to be carried out and the working conditions of the IRB 4400:

• Calendar time: specified in months regardless of whether the system isrunning or not.

• Operating time: specified in operating hours. More frequent running meansmore frequent maintenance activities.

• SIS: specified by the robot's SIS (Service Information System). A typicalvalue is given for a typical work cycle, but the value will differ depending onhow hard each part is run. The SIS used in M2000 and M2000A is furtherdescribed in the section Service Information System, M2000 on page 125.The SIS used in M2004 is further described in theOperatingmanual - ServiceInformation System.


3 Maintenance3.3.1 Specification of maintenance intervals

3.3.2 Maintenance schedule

GeneralThe robot must be maintained regularly to ensure proper function. The maintenanceactivities and intervals are specified in the table below.Unexpected situations that arise prompt inspection of the robot. Any damage mustbe attended to immediately!The inspection intervals do not specify the life of each component.

Activities and intervals (protection Standard)The table below specifies the required maintenance activities and intervals.

Detailed in sectionIntervalEquipmentMaintenanceactivity

Replacing the SMB battery onpage 108

36 months orbattery lowalert i

Battery pack, meas-urement system oftype RMU101 orRMU102 (3-pole bat-tery contact)

Replacement

Replacing the SMB battery onpage 108

Battery lowalert ii

Battery pack, meas-urement system with2-pole battery con-tact, e.g. DSQC633A

Replacement

Replacement of signal cabling, up-per arm (option 042) on page 173

12,000 hrsSignal cabling, upperarm (option 042)

Replacement

Inspection of mechanical stop, axis1 on page 104

Regularly iiiMechanical stop, axis1

Inspection

Oil change, gearbox axis 4 onpage 119

12,000 hrs ivOil, gearbox axis 4Change

Oil change, gearbox axis 5 and 6(all robot versions) on page 122

12,000 hrs ivOil, gearbox axes 5and 6

Change

i The battery low alert (38213Battery 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 turnedon until the battery is to be replaced.See the replacement instruction for more details.

ii 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 therobot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetimecan be extended with a battery shutdown service routine. See Operating manual - IRC5 withFlexPendant for instructions.

iii Must be replaced if bent!iv The gearboxes are lubricated for life, which corresponds to 40,000 hours of operation if the robot

is operating with an ambient temperature of less than 40° C. If the temperature is higher, the oilmust be changed!



3 Maintenance3.3.2 Maintenance schedule

Activities and intervals (protection Foundry Prime)Robots working with water jet cleaning and that have the special tightness for thisapplication require special maintenance for proper function. The maintenance mustbe done according to the maintenance schedule in the Product Manual and thefollowing additional maintenance.

Detailed in sectionIntervalEquipmentMaintenanceactivity

Replacement of cable har-ness, axes 1-3 on page 143or Replacement of cableharness, axes 4-6 onpage 148

6 monthsIf required i

Cable harnessInspectionReplacement

Inspection of mechanicalstop, axis 1 on page 104

Regularly iiMechanical stop, ax-is 1

Inspection

Inspection of air hoses(FoundryPrime) on page106

6 monthsAir hosesInspection

Protecting the wrist flangefrom corrosion on page 95

6 mthsWrist rust protectionInspection

Inspection of surface treat-ment (Foundry Prime) onpage 107

6 months iiiSurface treatmentInspection

6 monthsBalancing deviceInspection

Changing and inspecting oilon page 115

6,000 hrs ivGear oil axes 1-6Changing

Replacing the SMB batteryon page 108

36 months or batterylow alert v

Battery pack, meas-urement system oftype RMU101 orRMU102 (3-pole bat-tery contact)

Replacement

Replacing the SMB batteryon page 108

Battery low alert viBattery pack, meas-urement system with2-pole battery con-tact, e.g. DSQC633A

Replacement

i Parts that need to be changed according to the maintenance schedule are not covered by warranty.ii Must be replaced if bent!iii Damage to painted surfaces must be repaired as soon as possible to avoid corrosion.iv The gearboxes are lubricated for life, which corresponds to 40,000 hours of operation if the robot

is operating with an ambient temperature of less than 40° C. If the temperature is higher, the oilmust be changed!

v The battery low alert (38213Battery 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 turnedon 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 therobot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetimecan be extended with a battery shutdown service routine. See Operating manual - IRC5 withFlexPendant for instructions.


3 Maintenance3.3.2 Maintenance schedule

Continued

3.4 General maintenance activities

3.4.1 Inspection of mechanical stop, axis 1

Location of mechanical stopThe mechanical stop on axis 1 is located on the frame as shown in the figure.

xx0300000182

Mechanical stop pin, axis 1A

Set screwB

Required equipment

NoteSpare part no.Equipment, etc.



Standard toolkit

These procedures include ref-erences to the tools required.

Other tools and procedures may berequired. See references to theseprocedures in the step-by-step in-structions below.

InspectionThe procedure below details how to inspect the mechanical stop on axis 1

WARNING

If the mechanical stop has been deformed after a hard collision, it must bereplaced!



3 Maintenance3.4.1 Inspection of mechanical stop, axis 1

InfoAction

DANGER

Turn off all:• electric power supply• hydraulic pressure supply• air pressure supply (do not turn off for Foundry

Prime robots!)to the robot, before entering the robot working area.

1

Check regularly that the stop pin is not bent or dam-aged in any other way.

2

Removal/refitting of themechanical stop is detailed insection Fitting, mechanicalstop axis 1 on page 79.

Note

If the mechanical stop pin has been deformed ordamaged, it must be replaced by a new one!

3

Also check that the stop pin is properly attached.4


3 Maintenance3.4.1 Inspection of mechanical stop, axis 1

Continued

3.4.2 Inspection of air hoses (Foundry Prime)

GeneralThe air hoses on Foundry Prime robots must be inspected for leakage every sixmonths.

Required equipment

Art. no.Equipment, etc.

-Leak detection spray

-Pressure gauge

-Cut off valve

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

NoteAction

Recommended pressure:Apply compressed air to the air connector onrobot base, and raise the pressure with theknob until the correct value is shown on thepressure gauge.

10.2-0.3 bar

A

B

C

xx0600003341

• A: Air Connection• B: Pressure gauge• C: Cut off valve

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

Close the cut off valve.2

The time is < 5 seconds:• If the answer is YES: Localize the

leakage by following the proceduresbelow.

• If the anser is NO: The system is OK.Remove the leak testing equipment.

3

Pressurize by opening the cut off valve.4

Spray suspected leak areas with leak detec-tion spray.Bubbles indicate a leak.

5

When the leak is localized: correct the leak.6


3 Maintenance3.4.2 Inspection of air hoses (Foundry Prime)

3.4.3 Inspection of surface treatment (Foundry Prime)

Introduction to inspection of surface treatmentDamage to painted surfaces must be repaired as soon as possible to avoidcorrosion. All painted surfaces on the robot must be inspected.

Required equipment

NoteEquipment, etc.

See Touch up paint for Foundry Prime robots inpartlistPart list on page 281.

Touch up paint Foundry Prime 2, grey

Additional equipment - Foundry Prime


Mercasol3HAC034903-001Rust preventive

3HAC026759-001Sikaflex 521FC

12340011-116Loctite 574

Brush

3HAC035355-001Foundry Prime touch up kit

Inspection and repair of surface treatmentUse this procedure to inspect the surface treatment on Foundry Prime robots.

InfoAction

Inspect all painted surfaces for damages.1

Repair damages as described in the instruc-tion included in the spare part kit.

2


3 Maintenance3.4.3 Inspection of surface treatment (Foundry Prime)

3.4.4 Replacing the SMB battery

Note

The battery low alert (38213 Battery charge low) is displayed when the batteryneeds to be replaced. The recommendation to avoid an unsynchronized robotis 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 orRMU102 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 batteryis 36 months if the robot is powered off 2 days/week or 18 months if the robot ispowered off 16 h/day. The lifetime can be extended for longer production breakswith a battery shutdown service routine. See Operating manual - IRC5 withFlexPendant for instructions.

Location of battery packThe battery pack is fit to the serial measurement unit, located inside the base. Toaccess the unit and battery pack, the rear cover plate shown in the figure belowmust be removed.

xx0300000106

Rear cover plateA

Required equipment

Note

There are two variants of SMB units and batteries. One with 2-pole battery contactand one with 3-pole battery contact. The variant with the 3-pole battery contacthas longer lifetime for the battery.It is important that the SMB unit uses the correct battery. Make sure to order thecorrect spare parts. Do not replace the battery contact!

NoteEquipment, etc.

Serial measurement unit on page 288Battery pack

The contents are defined in section Contents,standard toolkit on page 277.

Standard toolkit



3 Maintenance3.4.4 Replacing the SMB battery

NoteEquipment, etc.


Other tools and procedures may be re-quired. See references to these proced-ures in the step-by-step instructions be-low.

Replacement, battery packThe procedure below details how to replace the battery pack in the serialmeasurement unit.

Info/IllustrationActionStep

xx0200000023

1

WARNING

The unit is sensitive to ESD. Before handling the unitplease read the safety information in the sectionWARNING - The unit is sensitive to ESD! on page 49

Set the robot to the MOTORS OFF operating mode.2This way the robot does not need to be calibratedafter the battery change.

Shown in the figure Locationof battery pack on page 108.

Remove the rear cover plate from the base.3

Loosen the battery terminals from the serial measur-ing board and cut the clasps that keep the batterypack in place.

4

Remove the old battery pack.5

Fit a new battery pack with two clasps and connectthe terminals to the serial measuring board.

6


3 Maintenance3.4.4 Replacing the SMB battery

Continued

3.4.5 Cleaning, robot

WARNING

Turn off all electrical power supplies to the manipulator before entering its workspace.

GeneralTo secure high uptime it is important that the robot is cleaned regularly. Thefrequency of cleaning depends on the environment in which the robot works.Different cleaning methods are allowed depending on the type of protection of therobot.

Note

Always check the serial number label for verification of the robot protection type.

Cleaning activitiesThese instructions specify allowed cleaning methods for each type of protection.

Cleaning methodProtectiontype

High pressure water orsteam

Rinse with waterWipewith clothVacuumcleaner

NoYes. It is highly re-commended thatwater contain arust-preventionsolution and thatthe robot be driedafterwards.

Yes. With lightcleaning deter-gent.

YesStandard

Yes i . It is highly recom-mended that water andsteam contains rust pre-ventive. If cleaning deter-gents are used they mustbe approved by ABB forFoundry Prime robots.

Yes. It is highly re-commended thatwater contain arust-preventionsolution.

Yes. Withcleaning deter-gent approvedby ABB, spiritor isopropyl al-cohol.

YesFoundryPrime

See Approved cleanersand detergents onpage 112.

i Perform according to section Cleaning with water and steam on page 110.

Cleaning with water and steamCleaning methods that can be used for ABB robots with protection Standard,Foundry Plus, Wash and Foundry Prime.

NoteEquipment, etc.

Vacuum cleaner

For Foundry Prime robots, only washing detergentsapproved by ABB shall be used. SeeApproved cleanersand detergents on page 112.

Cloth with mild detergent



3 Maintenance3.4.5 Cleaning, robot

NoteEquipment, etc.• Max. water pressure at the nozzle: 700 kN/m2

(7 bar) i

• Fan jet nozzle should be used, min. 45° spread• Distance from nozzle to encapsulation: min. 0.4

m• Flow: max. 20 liters/min i .

Water cleaner

• Water pressure at nozzle: max. 2,500 kN/m2 (25bar)

• Type of nozzle: fan jet, min. 45° spread• Distance from nozzle to encapsulation: min. 0.4

m• Water temperature: max. 80° C

Steam cleaner

i Typical tap water pressure and flow

Cleaning for Foundry Prime robots

Washing detergents• Only washing detergents approved by ABB shall be used. See Approved

cleaners and detergents on page 112.• The washing detergent must be cleansed continuously.• The washing detergent must contain rust inhibitor.• The detergent pH value and concentration must be checked regularly.• Maximum allowed pH of the washing detergent is 9.0, if not stated otherwise.• 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 lifeof the robot and its components.

• Recommendations given by the detergent manufacturer for the specificdetergent in question must be followed.

Note

If the pH value or the detergent concentration is varying from its originalspecification, it can become very corrosive.

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 brokenduring testing, installation, or repair work. Use the touch up kit available forFoundry Prime (article number 3HAC035355-001) to repair any damages in thepaint.




Continued

Approved cleaners and detergentsOther cleaners/detergents must be approved by ABB before use. Contact ABBRobotics Sales Support for latest information, or review latest released list ofapproved cleaners/detergents.

Approved cleaners and detergents for grey robots• Only washing detergents approved by ABB shall be used.• Currently approved cleaners/detergents (2013-03-04)

Approved for grey robots iManufacturerTested washing detergent

YesKlutheHakupur 70-3

YesKlutheHakupur 405

YesKlutheHakupur 218-4 Konz


YesHenkelP3- neutracare 3300




YesHenkelP3- neutrapon 5088

YesECOLABP3-topax 12

NoCastrolTechniclean HP ii

YesCastrolTechniclean S400

YesCastrolTechniclean S-RP

YesCastrolFlexiclean CPL

YesOemetaHycut 370

YesOemetaHycut 375

YesOemetaHycut CL500

YesOemetaHycut CL600

YesOemetaHygrind

YesPetroferEmulcut 2555-W

YesPetroferEmulcut 3500-M

YesFuchsRenoclean VR 1021 CXV

YesQuakerQuakerclean 624 CP

YesVan ErpVE 1015-2

YesPetroferFerroclean A 185

YesPetroferFerroclean N-AL 1

YesPetroferFerroclean N600

YesFuchs EuropeHono Aqua Plus 2

YesHoughtonCerfa-Kleen 5285

YesSurTech Germ.SurTec 010

YesNCOC INC.NC 1314




Continued

Approved for grey robots iManufacturerTested washing detergent

YesNCOC INC.NC 3098i Foundry Prime 2ii Castrol Techniclean HP has previously been approved, but is no longer approved to use in new

installations with Foundry Prime robots. For existing installations ABB recommends changing toanother detergent, for example Castrol Flexiclean CPL. No new installations are allowed with CastrolTechniclean HP.

Approved cleaners and detergents for orange robots• Only washing detergents approved by ABB shall be used.• Currently approved cleaners/detergents (2013-02-26)

Approved for orange robots iManufacturerTested washing detergent



NoKlutheHakupur 70-3 ii

NoHenkelP3- neutracare 3300 ii

NoHenkelP3- neutracare 200




NoHenkelP3- neutrasel 5225

NoHenkelP3- neutrapon 5020

NoCastrolTechniclean HP ii

YesCastrolProduct SW 3505

YesMac DermidSintKlin EM

NoOemetaHycut CL 370 ii

NoOemetaHycut CL 375 ii

NoOemetaHycut CL500

NoOemetaHycut CL600

YesPetroferFeroclean BMW-DGI-MOD

NoPetroferFerroclean N-AL 1

NoQuakerQuakerclean 624 MPCi Foundry Prime 1ii This detergent has previously been approved. ABB strongly recommends changing to another

detergent. No new installations are allowed with this detergent.

Washing without detergentIf the washing is performed without detergent, the water must contain rust inhibator.

CablesMovable cables need to be able to move freely:

• Remove waste material, such as sand, dust and chips, if it prevents cablemovement.




Continued

• Clean the cables if they have a crusty surface, for example from dry releaseagents.

Dos and don'ts!The section below specifies some special considerations when cleaning the robot.Always!

• Always use cleaning equipment as specified above! Any other cleaningequipment may shorten the life of the robot.

• Always check that all protective covers are fitted to the robot before cleaning!Never!

• Never point the water jet at connectors, joints, sealings, or gaskets!• Never use compressed air to clean the robot!• Never use solvents that are not approved by ABB to clean the robot!• Never spray from a distance closer than 0.4 meters!• Never remove any covers or other protective devices before cleaning the

robot!



Continued

3.5 Changing and inspecting oil

3.5.1 Type of lubrication in gearboxes

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

CAUTION

Always read the specific instructions for Foundy Prime robots before doing anyrepair work, see Replacing parts on Foundry Prime robots on page 140.

Location of gearboxesThe figure shows the location of the gearboxes.

Type and amount of oil in gearboxesInformation about the type of lubrication, article number as well as the amount inthe specific gearbox can be found in Technical reference manual - Lubrication ingearboxes. Document number is presented in References on page 10. In order toalways get the latest information of updates about lubrication in gearboxes, alwayscheck on ABB Library for the latest revision of the manual. A new revision will bepublished on ABB Library immediatly after any updates.Before starting any inspection, maintenance, or changing activities of lubrication,always check ABB Library for the latest revision of this manual. The revision ofthe manual published on the Documentation DVD (released twice a year) will onlycontain the latest updates when the Documentation DVD is released. Any updatesof the manual in between these releases will be published on ABB Library. Thereforethe manual published on the documentation DVD may not contain the latest updatesabout lubrication. If ABB Library cannot be reached, contact the local ABB Serviceorganisation for more information.

Equipment

NoteEquipment

Includes pump with outlet pipe.Oil dispenserUse the suggested dispenser or a similar one:

• Orion OriCan art. no. 22590 (pneumatic)

Nipple for quick connect fitting, with o-ring


3 Maintenance3.5.1 Type of lubrication in gearboxes

3.5.2 Inspection of oil levels

Location of oil plugs, axes 2 and 3The oil plug, filling for the gearbox unit, axes 2 and 3, is located as shown in thefigure below. The figure shows the location of the axis-2-side and is the same onthe opposite side.

xx0300000331

Oil plug, fillingA

Location of oil plugs, axis 4The axis 4 gearbox has one oil plug for draining and one oil plug for filling, locatedas shown in the figure below.

xx0300000220

Upper oil plug, fillingA

Lower oil plug, drainingB



3 Maintenance3.5.2 Inspection of oil levels

Location of oil plugs, axes 5 and 6 (all robot versions)The wrist unit has two oil plugs for draining and one oil plug for filling, located asshown in the figure below.

xx0300000223

Oil plug, draining (2 pcs, the other oil plug not shown in figure)A

Oil plug, filling (also used for draining)B

Required equipment



3HAC17594-1

Standard toolkit



Inspection, oil level axis 2-3The procedure below details how to inspect the oil level of the gearbox unit, axes2-3.


Shown in the figure Locationof oil plugs, axes 2 and 3 onpage 116.

Remove the oil plug, filling.1

The oil must cover at leasthalf of the lower arm bearing!

Measure the oil level from the oil plug hole.Required oil level: 225 mm ± 25 mm.

2

Where to find type of oil andtotal amount is detailed inType and amount of oil ingearboxes on page 115.

Fill or drain, if necessary.3

Clean and refit the oil plug.4




Continued

Inspection, oil level axis 4The procedure below details how to inspect the oil level of the gearbox, axis 4.

WARNING

Changing and draining gearbox oil may require handling hot oil of up to 90 °C!Make sure that protective gear like goggles and gloves are always worn duringthis activity.Also, be aware of possible pressure build up in gearbox! When opening the oilplug, there may be pressure present in the gearbox, causing oil to spray fromthe opening!

WARNING

When filling gearbox oil, do not mix different types of oil as this may cause severedamage to the gearbox! Always use the type of oil specified by the manufacturer!If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB forfurther instructions!


Move the upper arm to a horizontal position (calibra-tion position).

1

Shown in the figure Locationof oil plugs, axis 4 onpage 116.

Remove the upper oil plug, filling.2

Required oil level: 4 mm to the edge of the oil plughole.

3


Fill with lubricating oil, if necessary.4

Refit the oil plug.5

Inspection, oil level axis 5 and 6 (all robot versions)The procedure below details how to inspect the oil level of wrist unit, axis 5 and 6for all robot versions.


Move the robot to the calibration position.1

Shown in the figure Locationof oil plugs, axes 5 and 6 (allrobot versions) on page117.

Remove one of the oil plugs, draining at the rear ofthe wrist.

2

Required oil level: on level with the edge of the oilplug hole.

3


Fill with lubricating oil, if necessary4

Refit the oil plug.5



Continued

3.5.3 Oil change, gearbox axis 4

Location of oil plugsThe axis 4 gearbox has one oil plug for draining and one oil plug for filling, locatedas shown in the figure below.

xx0300000220

Upper oil plug, fillingA

Lower oil plug, drainingB

Required equipment


Information about the oil is found inTechnical reference manual - Lubrica-tion in gearboxes.

-Lubricating oil

See Type and amount of oil in gear-boxes on page 115.



The capacity of the vessel must besufficient to take the complete amountof oil.

Oil collecting vessel



DrainingThe procedure below details how to drain the oil from the gearbox, axis 4.

Tip

When changing gearbox oil, first run the robot for a time to heat up the oil. Warmoil drains quicker than cold oil.



3 Maintenance3.5.3 Oil change, gearbox axis 4

WARNING



Move the arms backward and the upper arm to anearly vertical position.

1

Shown in the figure Locationof oil plugs on page 119.

Remove the lower oil plug, draining and drain the oilinto an oil collecting vessel.

2

Capacity of the oil collectingvessel is specified in Re-quired equipment onpage 119.


FillingThe procedure below details how to refill the oil to the gearbox, axis 4.

Note

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

WARNING


WARNING

When filling gearbox oil, do not overfill, since this could lead to internalover-pressure inside the gearbox which in turn may:

• - damage seals and gaskets• - completely press out seals and gaskets• - prevent the manipulator from moving freely


Move the upper arm to a vertical position (rear endupwards).

1




Continued



Remove the upper oil plug, filling.2


Fill the gearbox with lubricating oil.3

Correct oil level is specifiedin section Inspection of oillevels on page 116.




Continued

3.5.4 Oil change, gearbox axis 5 and 6 (all robot versions)

Location of oil plugsThe wrist unit has two oil plugs for draining and one oil plug for filling, located asshown in the figure below.

xx0300000223

Oil plug, draining (2 pcs, the other oil plug not shown in figure)A

Oil plug, filling (also used for draining)B

Required equipment


Information about the oil is found inTechnical reference manual - Lubrica-tion in gearboxes.

-Lubricating oil

See Type and amount of oil in gear-boxes on page 115.



The capacity of the vessel must besufficient to take the complete amountof oil.

Oil collecting vessel



Draining oilThe procedure below details how to drain the oil from the wrist unit (axis 5 and 6).

Tip

When changing gearbox oil, first run the robot for a time to heat up the oil. Warmoil drains quicker than cold oil.



3 Maintenance3.5.4 Oil change, gearbox axis 5 and 6 (all robot versions)

WARNING



Move the upper arm to a horizontal position and turnaxis 4 to the calibration position.

1

Turn axis 4, 135°.2


Remove the lower oil plug, draining at the rear of thewrist.

3

Capacity of oil collectingvessel is specified in Re-quired equipment onpage 122.

Remove the other oil plug, draining.4

Move axis 3 up -15° and let the oil run out for acouple of minutes.

5


Turn axis 4 so that the oil plug, filling is facingdownwards.

6

Remove the oil plug, axis 5 to drain the oil.7

Move axis 3 down to 0°.8

Move axis 4 backwards and forwards a couple oftimes to drain all the oil.

9

Clean and refit the both oil plugs, draining.10

Filling oilThe procedure below details how to fill oil to the wrist unit (axis 5 and 6).

Note

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

WARNING





Continued

WARNING

When filling gearbox oil, do not overfill, since this could lead to internalover-pressure inside the gearbox which in turn may:

• - damage seals and gaskets• - completely press out seals and gaskets• - prevent the manipulator from moving freely


Move the upper arm to a horizontal position and turnaxis 4 to calibration position.

1


Turn axis 4 so that the oil plug, filling is facing up-wards.

2


Fill the wrist with lubricating oil through the oil plughole, filling.Fill in intervals so that the oil runs into the wrist.

3

Correct oil level is specifiedin section Inspection of oillevels on page 116.

Clean and refit the oil plug, filling.4



Continued

3.6 Service Information System, M2000

3.6.1 Using the SIS system

GeneralThis is a brief description of how to use the Service Information System, SIS forM2000 robot systems. Details may be found in:

• Service Information System, SIS• Defining the SIS input parameters• Setting the SIS parameters• Importing/exporting SIS data• Reading the SIS output logs

The section is only valid for M2000 systems. For information regarding M2004robot systems, see additional documentation, Operating manual - ServiceInformation System. Article number is specified in section References on page10.

Basic procedure

ReferenceAction

These are described in Description ofService Information System (SIS) onpage 126.

Determine which of the system functionsyou require.

1

Recommendations on how to define theseare given in SIS system parameters onpage 129.

Define what values are adequate and suit-able for your application in your productionenvironment.

2

How to do this is detailed in Setting theSIS parameters on page 131.

Enter these parameters in the system.3

Run the robot in normal operation.4

The TPU displays for resetting any SISvalue are shown inDescription of ServiceInformation System (SIS) on page 126.

Reset the counter if a repair is made, or if acounter for any other reason is restarted.

5

How to access this is detailed in Readingthe SIS output logs on page 133.

When a time limit, set in the parameters, isexceeded, a message may be read on theTech Pendant Unit (TPU).

6

These are described in Exporting the SISdata on page 134.

If the log containing the message is to beavailable from an external PC, or if the SISparameters are to be entered from an extern-al PC, a set of software tools are availableto build such an application.

7


3 Maintenance3.6.1 Using the SIS system

3.6.2 Description of Service Information System (SIS)

GeneralService Information System (SIS) is a software function within the robot controller,which simplifies maintenance of the robot system. It supervises the operating timeand mode of the robot, and alerts the operator when a maintenance activity isscheduled.Maintenance is scheduled by setting the system parameters of the type SISParameters, see section Setting the SIS parameters on page 131. All systemparameters are described in User´s Guide - System Parameters.

Supervised functionsThe following counters are available:

• Calendar time counter, a general alarm based on calendar time• Operation time counter, a general alarm based on operational time• Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox

service interval• Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox



service intervalCounters are reset when maintenance has been performed.The counter status is displayed after running the service routine for maintenance.Status “OK” indicates that no service interval limit has been exceeded by thatcounter.

Calendar timeThis is a clock within the control system that keeps track of the service interval,based on calendar time.When the calendar time limit for maintenance is reached, a message is displayedon the TPU. How to access this is detailed in section Reading the SIS output logson page 133.The following information is available about the calendar time in the service routine.

Date when the counter was reset last time, i.e. after the last service.Prev service

Elapsed time since the counter was reset the last time.Elapsed time

Date when next scheduled service is planned. This date is calcu-lated using system parameters, as detailed in section Setting theSIS parameters on page 131.

Next service

Remaining time to next scheduled service date.Remaining time



3 Maintenance3.6.2 Description of Service Information System (SIS)

Operation timeThis is a function within the control system that keeps track of the amount of timethe "MOTORS ON" signal is active, i.e. the amount of time the robot is in theoperating mode.When the operation time limit for maintenance is reached, a message is displayedon the TPU. How to access this is detailed in section Reading the SIS output logson page 133.The following information is available about the operation time in the service routine.

The specified service interval until another service will be required.This parameter was entered manually as detailed in section Settingthe SIS parameters on page 131.

Service interval

Operation time since the service interval was set the last time.Elapsed time

Remaining operation time until the time set in service interval hasexpired.

Remaining time

GearboxBased on measurements, torque and RPM, for example, the system calculates anexpected service interval for each gearbox. When service is due, a message willbe shown on the TPU. How to access this is detailed in section Reading the SISoutput logs on page 133.The following information is available about the joint service status in the serviceroutine.

Service status for axis x, i.e. the automatically calculated timeparameter has not been exceeded.

Joint x OK

The service interval for the axis in question has been reached.Joint x NOK

No service time parameter calculation available.Joint x N/AApplies to axes 4 and 5 (IRB 6600 and IRB 7600).

The following information is available for the axis service status in the serviceroutine.

The consumed time as a percentage of the total amount of time.Consumed time

Operation time for axis x since calculation began.Elapsed time

Remaining operation time for axis x until the service time parametervalue has been reached.

Remaining time

Reset valuesCounters may be reset at any time by running the service routine.When resetting, the counter variables are reset. The variables are described insection Exporting the SIS data on page 134!

Service interval exceededWhen the service time has been exceeded for the selection made, an error message(Service interval exceeded!) is displayed.




Continued

No data availableWhen no data is available for the selection made, a message (No data available!)is displayed when trying to display the data.



Continued

3.6.3 SIS system parameters

GeneralThis section details the system parameters that may be set with estimated values.The values can be defined by the operating organization as knowledge of therobot's working conditions are accumulated.Since the counters are to be used for purposes defined by the user, ABB cannotgive any recommendations regarding their definitions.The figures below shows the options of parameters to be set.

en0200000049

Operation time limit (service level)The number of operation hours selected as service interval.E.g. by setting the value "20,000", the SIS will save this as the nominal time foractivating the alarm, not counting the percentage described below.

Operation time warningA percentage of the "Operation time limit" specified above.E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after anoperation time "Reset" was made the last time.

Calendar time limit (service level)The number of calendar years selected as service interval.E.g. by setting the value "2", the SIS will save this as the nominal time for activatingthe alarm, not counting the percentage described below.

Calendar time warningA percentage of the "Calendar time limit" specified above.E.g. by setting the value "90", the SIS will alert the operator after 90% of two years,i.e. 657 days after a calendar time "Reset" was made the last time.



3 Maintenance3.6.3 SIS system parameters

Gearbox warningA percentage of the gearbox service interval as calculated by the system. E.g. bysetting the value "90", the SIS will alert the operator after 90% of the expectedservice interval of each gearbox.The robot system automatically detects and stores all required variables to calculatethe expected service interval (estimated remaining lifetime) of each gearbox. Thisis done by extrapolating data from earlier operation into a function of time, usinga formula including:

• input and output torque• gearbox spindle speed• other variables


3 Maintenance3.6.3 SIS system parameters

Continued

3.6.4 Setting the SIS parameters

GeneralIf the SIS system is to function properly, a number of parameters must be set. Thisis detailed below.

Procedure M2000This is an instruction of how to enter SIS parameters to the M2000 robot system.

NoteAction

Detailed in the User's Guide.Open "System parameters"using the TPU.

1

xx0200000045

Go to "System paramet-ers/Manipulator/types 2".

2

en0200000046



3 Maintenance3.6.4 Setting the SIS parameters

NoteAction

en0200000047

Select "0 SIS parameters"and press "Enter".

3

xx0100000200

en0200000048

Select the required systemThe parameter list is dis-played.

4

en0200000049

Available parameters are described in section SIS systemparameters on page 129.

Select the required paramet-ers by stepping up anddown through the parameterlist.

5


3 Maintenance3.6.4 Setting the SIS parameters

Continued

3.6.5 Reading the SIS output logs

GeneralWhenever a set condition has expired (e.g. max allowed operation time beforeservice), a message to this effect will be shown in the Operational log.

Access to logsHow to open a log and show its contents is detailed in the User's Guide, chapterService.

Available messagesThe following messages may be shown:

Meaning:SIS message in thelog:

Available in:

The manually set calendar time limit has expired.How to set the limit is detailed in section Settingthe SIS parameters on page 131.

Service MessageService is due!X calendar dayssince last service.

Calendar time

Proceed with the required service as detailed inchapterRepair on page135 or chapterMaintenanceon page 99 depending on which type of service.

X number of calendar days remain until themanually set calendar time limit expires.

Service MessageX calendar days tonext service.

Calendar time

How to set the value determining when the mes-sage is to be shown, is detailed in section Settingthe SIS parameters on page 131.

The manually set operation time limit has expired.How to set the limit is detailed in section Settingthe SIS parameters on page 131.

Service MessageService is due!X production hourssince last service.

Operation time


X number of operation hours remain until themanually set operation time limit expires.

Service MessageX production hoursto next service.

Operation time


The automatically calculated gearbox time limithas expired.

Service MessageGearbox x requiresservice!

Gearbox time


X percent of gearbox hours remain until the auto-matically calculated gearbox time limit expires.

Service MessageX% of the service in-terval has expired forgearbox x!

Gearbox time



3 Maintenance3.6.5 Reading the SIS output logs

3.6.6 Exporting the SIS data

GeneralThis section describes the available variables for entering SIS parameters as wellas showing any values of exceeded time limits as detected by the SIS counters.In a M2000 robot system, the values can be read on a PC using "Webware SDK".How to access these variables and how to perform the actual programmingsequences are detailed in the robot system User's Guide.

DefinitionsThe table below defines the names and functions of all software variables availablefor communication between the SIS and an external computer.

FunctionCounter typeUnitSignal

The date on which the supervision was star-ted/reset last time.

Calendar timesecsisRestartDate

The number of hours since start/last reset.Calendar timesecsisCalendarT

Total number of operation hours since thesystem was started. Corresponds to the oper-ating time counter on the control cabinet.

Operation timesecsisTotRunT

The number of operation hours since start/lastreset of the operation time counter. Corres-ponds to the operating time counter on thecontrol cabinet.

Operation timesecsisRunT

Estimated life of gearbox axis 1Gearbox timehrssisL10h_1

Operation time of gearbox axis 1Gearbox timesecsisL10h_Time_1






Operation time of gearbox axis 6Gearbox timehrssisL10h_Time_6


3 Maintenance3.6.6 Exporting the SIS data

4 Repair4.1 Introduction

Structure of this chapterThis chapter describes all repair activities recommended for the IRB 4400 and anyexternal 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, forexample spare parts numbers, required special tools, and materials.The procedures are gathered in sections, divided according to the componentlocation on the IRB 4400.

Required equipmentThe details of the equipment required to perform a specific repair activity are listedin the respective procedures.The details of equipment are also available in different lists in the chapterReferenceinformation on page 269.

Safety informationThere are general safety information and specific safety information. The specificsafety information describes the danger and safety risks while performing specificsteps in a procedure. Make sure to read through the chapter Safety on page 17before commencing any service work.

Note

If the IRB 4400 is connected to power, always make sure that the IRB 4400 isconnected to earth before starting any repair work.For more information see:



4 Repair4.1 Introduction

4.2 General procedures

4.2.1 Mounting instructions for bearings

GeneralThis section describes how to mount and grease different types of bearings on therobot.

Equipment


Used to grease the bearings, if notspecified otherwise.

3HAB3537-1Grease

Assembly of all bearingsFollow the following instructions while mounting a bearing on the robot.

NoteAction

To avoid contamination, let a new bearing remain in its wrappinguntil it is time for fitting.

1

Ensure that the parts included in the bearing fitting are free fromburrs, grinding waste, and other contamination. Cast componentsmust be free of foundry sand.

2

Bearing rings, inner rings, and roller elements must not be subjec-ted to direct impact. The roller elements must not be exposed toany stresses during the assembly work.

3

Assembly of tapered bearingsFollow the preceding instructions for the assembly of the bearings when mountinga tapered bearing on the robot.In addition to those instructions, the following procedure must be carried out toenable the roller elements to adjust to the correct position against the race flange.

NoteAction

Tension the bearing gradually until the recommended pre-tension is achieved.

Note

The roller elements must be rotated a specified number of turns before pre-tensioning is carried out and also rotated during the pre-tensioning sequence.

1

Make sure the bearing is properly aligned as this will directly affect the durab-ility of the bearing.

2

Greasing of bearingsThe bearings must be greased after assembly according to the followinginstructions:

• The bearings must not be completely filled with grease. However, if spaceis available beside the bearing fitting, the bearing may be totally filled withgrease when mounted, as excessive grease will be pressed out from thebearing when the robot is started.



4 Repair4.2.1 Mounting instructions for bearings

• During operation, the bearing should be filled to 70-80% of the availablevolume.

• 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 Repair4.2.1 Mounting instructions for bearings

Continued

4.2.2 Mounting instructions for seals

GeneralThis section describes how to mount different types of seals onto the robot.

Equipment


Used to lubricate the seals.3HAB3537-1Grease

Rotating sealsThe 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.

NoteAction

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).

1

Inspect the sealing surface before mounting. If scratchesor damage are found, the seal must be replaced since itmay result in future leakage.

2

Art. no. is specified inEquipment on page 138.

Lubricate the seal with grease just before fitting. (Not tooearly - there is a risk of dirt and foreign particles adheringto the seal.)

3

Fill 2/3 of the space between the dust tongue and sealinglip with grease. The rubber coated external diameter mustalso be greased, unless otherwise specified.

Mount the seal correctly with a mounting tool.4Never hammer directly on the seal as this may result inleakage.



4 Repair4.2.2 Mounting instructions for seals

Flange seals and static sealsThe following procedure describes how to fit flange seals and static seals.

Action

Check the flange surfaces. They must be even and free from pores.1It is easy to check flatness using a gauge on the fastened joint (without sealing com-pound).If the flange surfaces are defective, the parts may not be used because leakage couldoccur.

Clean the surfaces properly in accordance with the recommendations of ABB.2

Distribute the sealing compound evenly over the surface, preferably with a brush.3

Tighten the screws evenly when fastening the flange joint.4

O-ringsThe following procedure describes how to fit o-rings.

NoteAction

Ensure that the correct o-ring size is used.1

Defective o-rings may not be used.Check the o-ring for surface defects, burrs,shape accuracy, and so on.

2

Defective o-rings may not be used.Check the o-ring grooves.3The grooves must be geometrically correct andshould be free of pores and contamination.

Lubricate the o-ring with grease.4

Tighten the screws evenly while assembling.5


4 Repair4.2.2 Mounting instructions for seals

Continued

4.2.3 Replacing parts on Foundry Prime robots

GeneralWhen replacing parts on a Foundry Prime robot, it is important to make sure thatafter the replacement, no surface without paint is exposed to the aggressive workingenvironment.

Required equipment

NoteSpare partsEquipment

Sikaflex 521 FC. Color white.Sealing compound

Width 6-9 mm, made of wood.Tooling pin

EthanolCleaning agent

Knife

Lint free cloth

MercasolRust preventive

Brush

The grey touch up paint is usedon all Foundry Prime robots, re-gardless of the original color ofthe robot

3HAC035355-001Touch up paint Foundry Prime 2,Grey

RemovingUse this procedure when removing a part for replacement on a Foundry Primerobot.

DescriptionAction

xx0900000121

Cut the paint with a knife in the joint betweenthe part that will be removed and the struc-ture, to avoid that the paint cracks.

1

Carefully grind the paint edge that is left onthe structure to a smooth surface.

2

Refitting

DescriptionAction

Use ethanol on a lint free cloth.Before the parts are refitted, clean the jointso that it is free from oil and grease.

1

Place the tooling pin in hot water.2



4 Repair4.2.3 Replacing parts on Foundry Prime robots

DescriptionAction

xx0900000122

Seal all refitted joints with Sikaflex 521FC.3

xx0900000125

Use the tooling pin to even out the surfaceof the Sikaflex seal.

4

Sikaflex 521FC skin dry time (15 minutes).Wait 15 minutes.5

3HAC035355-001Use Touch up paint Foundry Prime 2, greyto paint the joint.

Note

Always read the instruction in the productdata sheet in the paint repair kit for FoundryPrime.

6

Apply Mercasol on all screw heads and setscrews after tightening.

7


4 Repair4.2.3 Replacing parts on Foundry Prime robots

Continued

4.2.4 Performing a leak-down test

GeneralAfter refitting any motor and gearbox, the integrity of all seals enclosing the gearboxoil must be tested. This is done in a leak-down test.

Required equipment


3HAC0207-1Leakdown tester

-Leak detection spray

Procedure

NoteAction

Finish the refitting procedure of the motor or gear inquestion.

1

Art. no. is specified in Requiredequipment on page 142.

Remove the topmost oil plug on the gear in questionand replace it with the leakdown tester.Adapters, which are included in the leakdown testerkit, may be required.

2

Correct value:Apply compressed air and raise the pressure withthe knob until the correct value is shown on themanometer.

30.2 - 0.25 bar (20 - 25 kPa)

Disconnect the compressed air supply.4

If the compressed air is signific-antly colder or warmer than thegearbox to be tested, a slightpressure increase or decreasemay occur. This is quite normal.

Wait for approx. 8-10 minutes. No pressure loss maybe detected.

5

Was any pressure drop evident?6Localize the leak as detailed below.Remove the leakdown tester and refit the oil plug.The test is complete.

Spray suspected leak areas with leak detection spray.Bubbles indicate a leak.

7

When the leak has been localized, take the necessarymeasures to correct the leak.

8


4 Repair4.2.4 Performing a leak-down test

4.3 Complete robot

4.3.1 Replacement of cable harness, axes 1-3

Location of cable harness, axes 1-3The cable harness of axes 1-3 is located throughout the axis 1 of the robot asshown in the figure below. Also see the following figure for the view X-X.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000111

Rear cover plateA

Connectors at the base. Connectors at the rear cover plate: R1.MP, R1.SMB,R1.CP/CS, R2.MP4-6. Brake release connectors: R2.BU, R2.BU1-3, R2.BU4-6.Connectors at serial measurement unit: R2.SMB, R2.FB1-3, R2.FB4-6.

B



4 Repair4.3.1 Replacement of cable harness, axes 1-3

Location of cable harness, view X-XThe cable guides in the middle of axis 1 are located as shown in the figure below.

xx0300000110

Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1.C

Connection box, motor 2. Connectors at motor 2: R3.MP2, R3.FB2.D

Connection box, motor 3. Connectors at motor 3: R3.MP3, R3.FB3.E

Cable guides in the middle of axis 1G

Protection plateH

Required equipment


IRB 4400 (all models)3HAC5958-1Cable harness, axes 1-3

Between the motor and theconnection box, axes 1, 2and 3.

3HAC4432-1Gasket

Replace if damaged.

Content is defined in sec-tion Standard tools onpage 277.



Other tools and proced-ures may be required.See references to theseprocedures in the step-by-step instructions be-low.




Continued


See chapter Circuit dia-gram on page 301.

Circuit diagram

General calibration inform-ation is included in sectionCalibration on page 253.

Calibration Pendulum In-struction

Removal, cabling axes 1-3The procedure below details how to remove the cable harness from the axes 1-3.


DANGER



1

Shown in the figure Locationof cable harness, axes 1-3 onpage 143.

Remove the rear cover plate.2

Removal detailed in sectionRemoval, serial measurementunit on page 203.

Remove the serial measurement unit.3

Shown in the figure Locationof cable harness, axes 1-3 onpage 143.

Loosen the connectors R1.MP1, R2.FB1-3, R2.BU,R2.BU1-3. Also loosen the earth connections.

4

Cut all the ties around bundle.5

Remove the cable bracket inside the base.6

Shown in the figure Locationof cable harness, view X-X onpage 144.

Remove the cable guides and the protection plate in themiddle of axis 1.

7

Remove the covers from the connections boxes for themotors in axes 1-2-3.

8

Shown in the figure Locationof cable harness, view X-X onpage 144.

Loosen all the connectors to the motors of axes 1-2-3.9

Remove the connection boxes from the motors 1-2-3.10

Feed the cabling up through the middle of axis 1 andremove the complete cabling.Tip! Gather the loose cabling and connectors into apackage with tape in order to protect the connectors andmake the cabling easier to handle.

11




Continued

Refitting, cabling axes 1-3The procedure below details how to refit the cable harness to axes 1-3.


DANGER



1

Part no. is specified in Re-quired equipment on page144

Feed the cable harness, axes 1-3 through the protectionplate and down through the middle of axis 1.

Tip

Gather the loose cabling and connectors into a packagewith tape in order to protect the connectors and makethe cabling easier to handle.

2


Refit the connection boxes to the motors 1-2-3. Replacethe gaskets if they are damaged.

3

Shown in the figure Locationof cable harness, view X-X onpage 144

Reconnect the connectors in the motors 1-2-3.4

Shown in the figure Locationof cable harness, view X-X onpage 144

Refit the cable guide and the protection plate in themiddle of axis 1.

5

See chapter Exploded viewson page 291.

Secure the cabling with straps, according to foldout 3.6

Refit the cable bracket inside the base.7

See chapter Exploded viewson page 291.

Reposition the cabling inside the base according to fol-dout 4.

8

Reconnect all connectors at the base.9

Detailed in Refitting, serialmeasurement unit on page204

Refit the serial measurement unit.10

Shown in the figure Locationof cable harness, axes 1-3 onpage 143

Refit the rear cover plate.11

Refit the covers of the connection boxes.12

Calibration is detailed in aseparate calibration manualenclosed with the calibrationtools.

Recalibrate the robot!13

General calibration informationis included in section Calibra-tion on page 253.




Continued


DANGER

Make sure all safety requirements are met when perform-ing the first test run. These are further detailed in thesection DANGER - First test run may cause injury ordamage! on page 46.

14



Continued

4.3.2 Replacement of cable harness, axes 4-6

Location of cable harness, axes 4-6The cable harness of axes 4-6 is located throughout the robot as shown in thefigure below.Also see the following figure for the view X-X.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000112

Rear cover plateA

Connectors at the base. Connectors at the rear cover plate: R1.MP, R1.SMB,R1.CP/CS (customer connection), R2.MP4-6. Brake release connectors: R2.BU,R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB, R2.FB1-3, R2.FB4-6.

B

Connection box, motor 4, 5 and 6. Connectors to the motors at upper arm:R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3.FB5, R3.FB6. Customer connections:R2.CP, R2.CS.

F

Cable bracket inside the lower armI

Cable bracket at the upper armJ




Location of cable harness, view X-XThe cable guides in the middle of axis 1 are located as shown in the figure below.

xx0300000110

Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1.C

Connection box, motor 2. Connectors at motor 2: R3.MP2, R3.FB2.D

Connection box, motor 3. Connectors at motor 3: R3.MP3, R3.FB3.E

Cable guides in the middle of axis 1G

Protection plateH

Required equipment


IRB 4400 (all models)3HAC8304-1Cable harness, axes 4-6

3 pcs3HAB3676-1GasketBetween the motor andthe connection box.Replace if damaged.




Other tools and proced-ures may be required. Seereferences to these pro-cedures in the step-by-step instructions below.


Circuit Diagram




Continued


Calibration is detailed in aseparate calibrationmanual enclosed with thecalibration tools.


Art. no. is specified insection on page ? in part2 of the Product manual.

Removal, cabling axes 4-6The procedure below details how to remove the cable harness from the axes 4-6.


DANGER



1

Remove the cover ot the connection box formotors 4-5-6.

2

Shown in the figure Location of cableharness, axes 4-6 on page 148


Detailed in section Removal, serialmeasurement unit on page 203



Loosen the connectors R2.MP4-6, R2.FB4-6,R2.BU4-6, R1.CP/CS. Also loosen the earthconnections.

5

Cut all the straps around the bundle.6

Remove the cable bracket inside the base.7

Shown in the figureLocation of cable har-ness, view X-X on page 149

Remove the cable guides and the protectionplate in the midle of axis 1.

8

xx0300000113

Loosen the cable brackets (A) betweengearboxes 2 and 3 and cut the strap aroundthem.

9




Continued


Feed the cabling and the air hose, if any, upthrough axis 1.

Tip

Gather the loose cabling and connectors intoa package with tape in order to protect theconnectors and make the cabling easier tohandle.

10


Loosen the cable bracket inside the lowerarm and undo the two screws.

11


Loosen the cable bracket at the upper arm.12


Loosen all the connectors to the motors atthe upper arm and customer connections, ifany.

13

Remove the connection box together with thecabling.

14

Connection box, upper armThe figure below shows the location of the motors, connectors and cabling in theupper arm connection box.

xx0300000116

Axis 4 motorA

Connector R3.MP4A1

Connector R3.FB4A2

Axis 5 motorB

Connector R3.MP5B1




Continued

Connector R3.FB5B2

Axis 6 motorC

Connector R3.MP6C1

Connector R3.FB6C2

Protection plateD

Cable strap, indoorE

cable strap, outdoorF

Refitting, cabling axes 4-6The procedure below details how to refit the cable harness to the axes 4-6.


DANGER


Foundry Prime robots!)to the robot, before entering the robot workingarea.

1

Part no. is specified in Requiredequipment on page 149.

Check the position of the three gaskets, locatedbetween the motors and the connection box. Re-place them if damaged.

2

Refit the connection box.3Make sure the gaskets are seated properly!

Connectors and correct positioningare shown in the figure Connectionbox, upper arm on page 151.

Reconnect all the connectors and reposition thecabling inside the connection box using straps.

4

Shown in the figureConnection box,upper arm on page 151.

Refit the protection plate in the connection box.5

Run the cabling through the lower arm.6

Shown in the figure Location of cableharness, axes 4-6 on page 148.

Refit the cable bracket at the upper arm.7


Refit the cable bracket inside the lower arm.8

Shown in the figure Location of cableharness, view X-X on page 149.

Feed the cabling through the protection plate anddown through the axis 1.

9




Continued


xx0300000113

Refit the cable brackets (A) between the gearboxesof axes 2 and 3 and strap the cabling.

10

Refit the cable bracket inside the base.11

See chapter Exploded views onpage 291.

Put straps around the bundle and position thecabling at the base according to foldout 4.

12

Reconnect all the connectors at the base.13

Detailed inRefitting, serial measure-ment unit on page 204.

Refit the serial measurement unit.14


Refit the rear cover plate.15

Refit the cover of the connection box in the upperarm.

16

Calibration is detailed in a separatecalibration manual enclosed with thecalibration tools.


General calibration information isincluded in section Calibration onpage 253.

DANGER

Make sure all safety requirements are met whenperforming the first test run. These are further de-tailed in the section DANGER - First test run maycause injury or damage! on page 46.

18



Continued

4.3.3 Replacement of complete arm system

Location of complete arm systemThe complete arm system includes the lower arm and the complete upper arm, asshown in the figure below.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000143

Lower armA

Upper armB

Attachment screws and friction washers, lower armC

Parallel armD

V-ring between lower arm and gearbox axis 3E

Required equipment


2 pcs.3HAB3773-11V-ringOn both sides of the lowerarm, in the frame.

Used to grease sealings andbearings.

3HAB3537-1Grease

Content is defined in sectionStandard tools on page 277.




4 Repair4.3.3 Replacement of complete arm system




General calibration informa-tion is included in sectionCalibration on page 253.


Removal, complete arm systemThe procedure below details how to remove the complete arm system from therobot.


DANGER



1

CAUTION

The robot arm system weighs 245 kg.All lifting accessories used must be sizedaccordingly!

2

Detailed in sectionReplacement of tie rodon page 186.

Remove the tie rod.3

Detailed in section Replacement of com-plete arm system on page 154.

Remove the cabling down to axis 1.4




Continued


xx0300000142

Move the upper arm into a resting positionagainst the lower arm.Lock the upper arm in this position with se-curing slings around the lower and upper arm(A), as shown in the figure to the right.Note! If the arms are not properly secured,the upper arm may move during the lift andcause a drop of the complete arm system.

5

Note! The figure shows the IRB 4400.

Unload the weight of the arm system withlifting slings and a crane.

6

Detailed in section Removal, balancingdevice on page 195.

Remove the balancing device.7

Detailed in sectionReplacement of paral-lel arm / Replacement of bearing onpage 190.

Remove the parallel arm.8

Shown in the figure Location of completearm system on page 154.

Remove the attachment screws and frictionwashers, lower arm.

9

Lift away the complete arm system.Make sure the upper and lower arm areproperly secured to each other during the lift.

10

Refitting, complete arm systemThe procedure below details how to refit the complete arm system to the robot.


DANGER

Turn off all:• electric power supply• hydraulic pressure supply• air pressure supply (do not turn off

for Foundry Prime robots!)to the robot, before entering the robotworking area.

1




Continued


CAUTION


2

Part no. is specified inRequired equipmenton page 154

Check and grease both of the V-rings in theframe. Replace if damaged.

3

xx0300000142

Lift the arm system into mounting position.Make sure the arms are properly securedto each other (A), as shown in the figure tothe right.

4

10 pcs, M16x55. Tightening torque: 260 Nm.Secure the arm system to the gearbox axis2 with the attachment screws and frictionwashers.

5Shown in the figure Location of completearm system on page 154

Make sure both V-rings are seated properly!

Grease the bearing seating of the parallelarm in the lower arm, to prevent clickingduring operation.

6

Detailed in section Refitting, parallelarm/bearing on page 192

Refit the parallel arm.7

Detailed in section Refitting of balancingdevice on page 199

Refit the balancing device.8

Move the upper arm to a horizontal position.9

Detailed in section Refitting, tie rod onpage 188

Refit the tie rod.10

Detailed in section Refitting, cabling axes4-6 on page 152

Refit the cabling to the upper arm.11




Continued


Calibration is detailed in a separate calibra-tion manual enclosed with the calibrationtools.


General calibration information is includedin section Calibration on page 253.

DANGER

Make sure all safety requirements are metwhen performing the first test run. Theseare further detailed in the sectionDANGER- First test run may cause injury or damage!on page 46.

13



Continued

4.4 Upper arm

4.4.1 Replacement of complete upper arm

Location of upper armThe complete upper arm includes the wrist unit and is located as shown in thefigure below. (The figure shows the IRB 4400.)A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000129

Upper armA

Connectors of motors, axes 4, 5 and 6B

Connection box, upper armC

Calibration plate, axis 3D

VK coverE

KM nutF

ScrewG

BearingH

Sealing ringI

Shaft endJ



4 Repair4.4.1 Replacement of complete upper arm

Required equipment


Foundry (also used for Stand-ard)

3HAC17542-1Upper arm, without wristand motors

3HAC7877-1Sealing ring

3HAA2103-13Taper roller bearing

3HAC12165-1VK cover

3HAC4744-1Shaft end

Used to grease the bearing.3HAB3537-1Grease




Used to pull out the shaft.3HAC0163-1Dismounting tool

Used to fit the inner ring of thebearing.

3HAB1463-1Mounting tool

Contains two separate parts.

Used to evacuate air when re-fitting VK-cover, if the coverhas no grooves for venting.

3HAC8704-1De-air tool


Other tools and proced-ures may be required. Seereferences to these proced-ures in the step-by-step in-structions below.

Art. no. is specified in sectionCalibration on page 253.


Removal, upper armThe procedure below how to remove the complete upper arm from the robot.


DANGER



1

CAUTION

The robot upper arm weighs 180 kg.All lifting accessories used must be sizedaccordingly!

2

Move the upper arm to a horizontal position.3




Continued


Secure the weight of the upper arm with thelifting slings and a crane.

4

Detailed in section Removal, tie rod onpage 187


Shown in the figure Location of upper armon page 159

Loosen the connectors of motors, axes 4, 5and 6.

6


Remove the connection box, upper arm fromthe motors.

7


Remove the calibration plate, axis 3.8


Remove the VK covers on both sides of theupper arm.Be careful with the bearing beneath the cov-er! Make a hole in the outer edge of the coverand bend it away.

9


Undo the KM nuts.10


Remove the screws.11

Art.no. is specified inRequired equipmenton page 160

Pull out the shaft with the dismounting tool.Mark the shafts (left and right)!

12


Remove the sealings and bearings, if dam-aged.

13

Remove the upper arm from the manipulator.14

Refitting, upper armThe procedure below details how to refit the complete upper arm to the robot.


DANGER



1

CAUTION

The robot upper arm weighs 180 kg.All lifting accessories used must be sizedaccordingly!

2

Shown in the figure Location of upper armon page 159.

Fit the sealings and the outer ring of thebearings in the upper arm, if removed.The bearing must be completely filled withgrease.

3

Part no. is specified in Required equip-ment on page 160.




Continued


Lower the upper arm into mounting position.4


Refit both shaft ends.5



Insert both screws.6

2 pcs, tightening torque: 470 Nm.

Art. no. is specified in Required equip-ment on page 160.

xx0300000130

If the bearing is removed, the inner ring ofthe bearing is fitted as follows:

• Fit the holding-on tool (part A of themounting tool) on the right side of theupper arm (seen from behind).

• Fit the inner ring (C) of the bearing onthe left side of the upper arm, usingthe press tool (part B of the mountingtool).

• Remove the holding-on tool and fit theinner ring also on that side.

7

• A: Holding-on tool• B: Press tool• C: Inner ring

Locking liquid specified in Requiredequipment on page 160

Apply locking liquid on the threads of the KMnut.

8

Shown in the figure Required equipmenton page 160.

Tighten the KM nut...• on the left side, with torque 95 Nm in

order to center the upper arm• on the right side first with 105 Nm.

Then unscrew the KM nut and re-tighten it with torque 95 Nm.

Note! This procedure must be performedwithin 10 minutes, before the Loctite beginsto harden.

9


Fit new VK covers.Note! If the covers have no grooves forventing, the air must be evacuated by usingthe de-air tool (A). Also use a clamp as anaid in positioning the covers tilted, to avoidoverpressure.

10


xx0300000134

• A: De-air tool, used if the VK-coverhas no grooves for venting.

Detailed in section Replacement of com-plete upper arm on page 159.





Continued



Refit the calibration plate, axis 3.12


Refit the connection box.13


Reconnect the connectors to motors, axes4, 5 and 6.

14

Calibration is detailed in a separate calib-ration manual enclosed with the calibra-tion tools.



DANGER

Make sure all safety requirements are metwhen performing the first test run. These arefurther detailed in the sectionDANGER - Firsttest run may cause injury or damage! onpage 46.

16



Continued

4.4.2 Replacement of wrist unit

Location of wrist unitThe wrist unit is located in the upper arm as shown in the figure below. (Theillustration shows the IRB 4400.) Removal/refitting procedures differs dependingon robot version.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000150

Wrist unitA

O-ringB

Sealing surface between wrist unit and upper arm tubeC

Attachment screws and washersD

Required equipment


3HAB8271-1Wrist unit(IRB 4400)

21522012-541O-ring(IRB 4400)

Used to lubricate the o-ringgroove.

3HAB3537-1Grease



4 Repair4.4.2 Replacement of wrist unit


Loctite 57412340011-116

Flange sealing


3HAC17594-1

Standard toolkit



Art. no. is specified in sectionCalibration on page 253 .


Removal of wrist unitThe procedure below details how to remove the wrist unit from the robot.

Note

This component includes a complete unit comprising motors and gearboxes. Itis a replacement unit of complex design and should not normally be servicedon-site. Instead it should be sent to ABB for service.ABB recommends its customers to carry out only the following servicing andrepair work on this unit.


DANGER



1

CAUTION

The robot wrist unit weighs 48 kg.All lifting accessories used must be sizedaccordingly!

2

Draining is detailed in sections Oilchange, gearbox axis 5 and 6 (all robotversions) on page 122

Drain the oil from the wrist unit.3




Continued


xx0300000148

Remove the attachment screws and washers(A).

4

Wrist unit on robot version IRB 4400.

Remove the wrist unit from the upper arm.5

Refitting, wrist unit IRB 4400The procedure below details how to refit the wrist unit to robot versions IRB 4400/60and Foundry Prime.

Note

This component includes a complete unit comprising motors and gearboxes. Itis a replacement unit of complex design and should not normally be servicedon-site. Instead it should be sent to ABB for service etc.ABB recommends its customers carry out only the following servicing/repairwork on this unit.


DANGER



1

CAUTION

The robot wrist unit weighs 48 kg.All lifting accessories used must be sizedaccordingly!


Lubricate the o-ring groove in order to posi-tion the o-ring.Fit the o-ring to the wrist.

2

Shown in the figure Location of wrist uniton page 164.


Apply flange sealing to the surface of thewrist that will seal against the upper arm tube.

3

Sealing surface shown in the figure Loca-tion of wrist unit on page 164.




Continued


xx0300000148

Refit the wrist with attachment screws andwashers (A).

4

• A: 8 pcs, M10x35. Tighteningtorque: 41 Nm.

Detailed in section Oil change, gearboxaxis 5 and 6 (all robot versions) onpage 122.

Fill the wrist unit with oil.5




DANGER


7



Continued

4.4.3 Replacement of arm house unit, axis 4

Location of arm house unitThe arm house unit includes the axis 4 housing and the upper arm tube. It is locatedas shown in the figure below.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000183

Upper arm tubeA

Axis 4 housingB

Required equipment


Foundry, also used for Stand-ard.

3HAC17542-1Upper arm without wristand motors


3HAC17594-1

Standard toolkit







4 Repair4.4.3 Replacement of arm house unit, axis 4

Replacement, arm house unitThe procedure below details how to replace the arm house unit.

CAUTION

The complete arm house unit weighs 152 kg! All lifting equipment used must bedimensioned accordingly!


DANGER



1

Detailed in section Replacement of armhouse unit, axis 4 on page 168.

Remove the wrist unit.2

Detailed in section Removal of motor,axes 4, 5 and 6 on page 226.

Remove the motors for axes 4, 5 and 6.3

Detailed in section Replacement of armhouse unit, axis 4 on page 168.

Remove the arm house unit.4


Fit the new arm house unit.5

Detailed in section Replacement of wristunit on page 164.

Refit the wrist unit.6

Detailed in sections• Refitting of motor, axis 4 on

page 228• Refitting of motor, axis 5 on

page 231• Refitting of motor, axis 6 on

page 234

Refit the motors for axes 4, 5 and 6.7




DANGER


9


4 Repair4.4.3 Replacement of arm house unit, axis 4

Continued

4.4.4 Replacement of mechanical stop, axis 4

Location of mechanical stopThe mechanical stop of axis 4 is located in the upper arm as shown in the figurebelow. (The figure shows the IRB 4400.)A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000176

Mechanical stop axis 4A

Damper axis 4B

Attachment screws, mechanical stopC

Required equipment



3HAB3760-1Damper

Loctite 57412340011-116Flange sealing







4 Repair4.4.4 Replacement of mechanical stop, axis 4

WARNING


WARNING

When the damper is removed from axis 4, the axis does not have a mechanicalstop! If the robot is provided with cabling on the upper arm, the cabling can bedamaged when the function Resetting the work area for an axis is used, or if therobot is jogged uncalibrated.

Removal, mechanical stopThe procedure below details how to remove the axis 4 mechanical stop from therobot.


DANGER



1

Shown in the figure Locationof mechanical stop onpage 170.

Remove the mechanical stop by removing its attach-ment screws.

2


Rotate axis 4 so that the damper is visible. Removethe damper.

3

Refitting, mechanical stopThe procedure below details how to refit the axis 4 mechanical stop to the robot.


DANGER



1




Continued



Fit the damper to the axis 4.2

Part no. is specified in Re-quired equipment onpage 170.

Art. no. is specified in Re-quired equipment onpage 170.

Apply flange sealing to the stop.3


Fit the mechanical stop to the axis 4 with its attach-ment screws.

4

Part no. is specified in Re-quired equipment onpage 170.4 pcs, M8x16. Tighteningtorque: 24 Nm.



Continued

4.4.5 Replacement of signal cabling, upper arm (option 042)

Location of signal cabling, upper armThe signal cabling (option 042) runs along the upper arm as shown in the figurebelow.

xx0300000192

Wrist bracketA

Upper arm bracketB

Front and rear cable holdersC

Plastic hoseD

Required equipment


Includes signal/power cabling,necessary brackets, holdersetc.

3HAC8820-1Customer connection axis4


3HAC17594-1

Standard toolkit





4 Repair4.4.5 Replacement of signal cabling, upper arm (option 042)

Removal, signal cabling upper armThe procedure below details how to remove the signal cabling from the upper arm.


DANGER



1

Shown in the figure Location ofsignal cabling, upper arm onpage 173.

Remove the wrist bracket and the upper armbracket from the upper arm.

2

Shown in the figure Location ofsignal cabling, upper arm onpage 173.

Remove the front and rear cable holders fromthe tube shaft.

3

Disconnect the connectors at the rear of theupper arm.

4

Refitting, signal cabling upper armThe procedure below details how to refit the signal cabling to the upper arm.


DANGER



1

Fit transparent protection tape to the narrowpart of the tube shaft. Remove dirt and greasefrom the surface first!

2

Move axis 4 to its calibration position (0°).3




Continued


Location of the bracket is shownin the figure Location of signalcabling, upper arm on page 173.

xx0300000193

Refit the wrist bracket to the upper arm.4

• A: 2 pcs, M8x12.

Location of the bracket is shownin the figure Location of signalcabling, upper arm on page 173.

xx0300000194

Refit the upper arm bracket to the upper arm.5

• B: 3pcs, M8x12.

Slowly rotate axis 4 clockwise to its stop posi-tion.Constantly check that the cables are not fullyextended!Note! If the cables gets fully extended, stop therotation and let out more cable from the rearcable holder. This is done by loosening the greyholders and pushing ot the cables by hand.

6

Complete the rotation.Note!Do not tighten the rear cable holder, leaveit open!

7




Continued


xx0300000197

First fit the front cable holder around the tubeshaft.Run the black plastic hose through the foot ofthe holder.Fit the rear cable holder around the tube shaftin the same way.

8

• A: Plastic hose• B: Cable holder

Also see the figure Location ofsignal cabling, upper arm onpage 173.

Move axis 4 from one extreme limit to the otherand back again.

xx0100000003

Caution!Check the cables during movement:

• the cables must not be fully extended!• the cables and air hose must not touch

any moving parts of the arm!• the fixing rings must always slide

smoothly with no excessive pulling!

9

Adjust the length of the cables by pushing andpulling the cables through the inner holders,which are still loose.Note! When axis 4 is moving, no stretching ofthe cables should be felt.

10

Tighten the holders by hand. Do not use tools.11

Reconnect the connectors at the rear end ofthe upper arm.

12

Connect the air hose.13

Secure the cables and air hose together withcable straps above the motors.

14

DANGER

Make sure all safety requirements are met whenperforming the first test run. These are furtherdetailed in the section DANGER - First test runmay cause injury or damage! on page 46.

15



Continued

4.4.6 Measuring the play, axis 5

GeneralAfter reassembly due to repair work or any other reason, the play in axis 5 and 6must be checked to ensure the repetition accuracy of the robot positioning. Theprocedure for axis 5 is detailed below.

Required equipment



-Standard toolkit

3HAB1611-6Measuring tool, play


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





12340011-116Loctite 574

Brush


Measurement, axis 5The procedure below details how to measure the play of axis 5.

Note

The measuring tool and measuring values differ depending on robot version!

InfoAction

DANGER



1

Move the robot to calibration position andturn the axis 4 90°.

2


Fit the measuring tool, play to the turningdisk.

3



4 Repair4.4.6 Measuring the play, axis 5

InfoAction

xx0300000186

Apply load F in one direction, as shown inthe figure to the right.

Note

Different load and distances for the differ-ent robot versions, as specified to the right!

4

Values for robot version IRB 4400• A: Measuring tool, play• B: 100mm• C: 140mm• F: 200N

Remove the load and set the dial indicatorto zero.

5

xx0300000187

Apply load F in the opposite direction, asshown in the figure to the right.

6

Values for robot version IRB 4400:• A: Measuring tool, play• B: 100mm• C: 140mm• F: 200N

The maximum play allowed at the givendistance from the center of axis 5 is, forrobot version

• IRB 4400: 0.20mm

Remove the load and measure the play byreading the dial indicator.

7



Continued

4.4.7 Measuring the play, axis 6

GeneralAfter reassembly due to repair work or any other reason, the play in axis 5 and 6must be checked to ensure the repetition accuracy of the robot positioning. Theprocedure for axis 6 is detailed below.

Required equipment



-Standard toolkit

3HAB1611-6Measuring tool, play


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





12340011-116Loctite 574

Brush


Measurement, axis 6The procedure below details how to measure the play in axis 6.

Note

The measuring tool and measuring values differ depending on robot version!

InfoAction

DANGER

Turn off all:• electric power supply• hydraulic pressure supply• air pressure supply (do not turn

off for Foundry Prime robots!)to the robot, before entering the robotworking area.

1

Art. no. is specified in Required equipmenton page 179.

Fit themeasuring tool, play to the turningdisk.

2




InfoAction

xx0300000188

Attach a weight (m) at a distance (B) fromthe wrist flange, in order to avoid the ef-fects of play on axis 5.

Note

Different weight and distance for the dif-ferent robot versions, as specified to theright!

3

Values for robot versions IRB 4400:• A: Measuring tool, play• B: 100mm• m: 20 kg

xx0300000189

Apply load F in one direction.

Note

Different load and distances for the differ-ent robot versions, as specified to theright!

4


Remove the load and set the dial indicat-or to zero.

5

xx0300000190

Apply load F in the opposite direction,as shown in the figure to the right.

6





Continued

InfoAction

The maximum play allowed at the givendistance (B) from the center of axis 6 is, forrobot version:

• IRB 4400: 0.15mm

Remove the load and measure the playby reading the dial indicator.

7



Continued

4.5 Lower arm

4.5.1 Replacement of lower arm

Location of lower armThe lower arm is located as shown in the figure below. (The figure shows the IRB4400.)A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000141

Lower armA



4 Repair4.5.1 Replacement of lower arm

Attachment screws and friction washers, lower armB

Calibration plate, axis 2C

DamperD

Parallel armE

V-ring between lower arm and gearbox axis 3F

Required equipment


3HAC5955-1Lower arm(IRB 4400)

2 pcs3HAB3773-11V-ringOn both sides of the lower arm,in the frame.

Used to grease sealings andbearings.

3HAB3537-1Grease







Removal, lower armThe procedure below details how to remove the lower arm from the robot.


DANGER



1

CAUTION

The robot lower arm weighs 65 kg.All lifting accessories used must be sizedaccordingly!

2

Detailed in section Replacement oflower arm on page 182.

Remove the cabling down to axis 1.3




Continued


Detailed in section Replacement oflower arm on page 182.

Remove the complete upper arm.4

Attach a crane to the lower arm and unloadthe weight.

5

Detailed in section Removal, balan-cing device on page 195.

Remove the balancing device.6

Detailed in section Replacement ofparallel arm / Replacement of bearingon page 190.


Shown in the figure Location of lowerarm on page 182.

Remove the attachment screws and frictionwashers, lower arm.

8

Remove the lower arm from the manipulator.9

Refitting, lower armThe procedure below deatails how to refit the lower arm to the robot.


DANGER



1

CAUTION

The robot lower arm weighs 65 kg.All lifting accessories used must be sized accord-ingly!

2

Part no. is specified in Re-quiredequipmentonpage183

Move the damper and the calibration plate from theold to the new lower arm.

3


Check and grease both V-rings in the frame. Replaceif damaged.

4

Lift the lower arm and lower it into mounting position.5Make sure both V-rings stay seated properly!

10 pcs. M16x55. Tighteningtorque: 260 Nm.

Refit the lower arm to the gearbox axis 2 with attach-ment screws and friction washers, lower arm.

6

Shown in the figure Locationof lower arm on page 182

Grease the bearing seating of the parallel arm in thelower arm, to prevent clicking during operation.

7

Detailed in section Refitting,parallel arm/bearing onpage 192


Detailed in section Refittingof balancing device onpage 199

Refit the balancing device.9




Continued


Detailed in section Refitting,upper arm on page 161

Refit the upper arm.10

Detailed in section Refitting,cabling axes 4-6 on page152

Refit the cabling.11




DANGER


13



Continued

4.5.2 Replacement of tie rod

Location of tie rodThe tie rod is located as shown in the figure below. (Figure shows the IRB 4400.)A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000117

Tie rodA

Attachment screwB

WasherC

O-ringD

Sealing, outsideE

Spherical roller bearingF

Sealing, insideG

Required equipment


Replace if damaged.3HAB3704-1Washer



4 Repair4.5.2 Replacement of tie rod


3HAB3772-23O-ring

3HAC3297-1Sealing, outside

3HAA2167-11Spherical roller bearing

3HAC3990-11Sealing, inside

Used to lubricate the shafton the robot where the tierod is to be refitted.

3HAB3537-1Grease


Content is defined in sectionStandard tools on page277.


2 pcsPuller toolUsed to pull out the tie rodalternately at the upper andlower end if the tie rod.

Used to press in the spheric-al roller bearing.

3HAB1598-1Press tool

2 pcs.3HAB1529-1Press tool, p-armUsed to press on the tie rodalternately at the upper andlower end of the tie rod.





Removal, tie rodThe procedure below details how to remove the tie rod from the robot.


DANGER



1

Lock the upper arm in a horizontal position with helpof a crane or similar.

2

Shown in the figure Locationof tie rod on page 186.

Remove the two attachment screws.3

Shown in the figure Locationof tie rod on page 186.

Remove the two washers, o-rings and sealings, out-side from the tie rod.

4




Continued


Insert a screw in each center, to be used as a sup-port.

5

Use two puller tools to pull out the tie rod, one at theupper and lower end.Pull alternately at the upper end and at the lower endwith the puller tools!

6

The part no. for new bear-ings is specified in sectionReplacement of tie rod onpage 186.

Remove the bearings if they are to be replaced.7

Refitting, tie rodThe procedure below details how to refit the tie rod on to the robot.


DANGER



1

Part/Art. no. is specified inRequired equipment onpage 186

If the bearings are to be replaced, fit new sphericalroller bearings and new sealings, inside to the tierod.Use the press tool.

2

Lift the tie rod to its mounting site. Make sure the tierod is refitted with the correct end up!

3

Art. no. is specified in Re-quiredequipmentonpage186

Grease the shaft on the robot and refit the tie rod onto the robot using two press tolls for p-arm.Press alternately at the upper and lower end with thepress tools!

4


Fit the sealings, outside to the tie rod.5


Fit the o-rings to the tie rod.6

Shown in the figure Locationof tie rod on page 186

Refit the washers and attachment screws usinglocking liquid.

7

Locking liquid is specified inRequired equipment onpage 186







Continued


DANGER


9



Continued

4.5.3 Replacement of parallel arm / Replacement of bearing

Location of parallel armThe parallel arm is located on the robot, as shown in the figure below. (The figureshows the IRB 4400.)The bearing of the parallel arm is shown in the enlarged view.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000128

Parallel armA

Attachment screwB

WasherC

V-ring on parallel armD

BearingE

SealingF



4 Repair4.5.3 Replacement of parallel arm / Replacement of bearing

Required equipment


3HAB3732-11V-ring sealing

3HAC10905-1Groove ball bearing

3HAB3749-1Sealing ring

Used to lubricate the bear-ings and sealings.

3HAB3537-1Grease



Used to lift the parallel arm.3HAB1412-1Lifting tool





Removal, parallel arm/bearingThe procedure below details how to remove the parallel arm from the robot duringrepair work. It also details how to remove the bearing from the parallel arm in orderto replace it.


DANGER



1

CAUTION

The parallel arm system weighs 118 kg.All lifting accessories used must be sizedaccordingly!

2

Detailed in Replacement of tie rod onpage 186.



Fit the lifting tool to the parallel arm.Unload the arm with a crane.

4




Continued


xx0300000127

Loosen the attachment screws (A) so thatthe cabling can be moved slightly.

5

Remove the 10 attachment screws andthe washer that holds the parallel arm togearbox axis 3.

6

Lift away the parallel arm from the robot.7

If they are to be replaced, remove thebearing and sealings from the parallelarm.

8

Refitting, parallel arm/bearingThe procedure below details how to refit the parallel arm on to the robot duringrepair work. It also details how to fit a new bearing to the parallel arm asreplacement.


DANGER



1

CAUTION

The parallel arm system weighs 118 kg.All lifting accessories used must besized accordingly!

2

Part no. is specified in Required equip-ment on page 191

Fit the new V-ring to the parallel arm.3


If the bearing is to be changed:• Heat the new groove ball bearing

to 170°C.• Fit the bearing to the parallel arm.

If the old bearing is kept:• Grease the bearing.

4


Fit the sealing ring to the bearing.5




Continued


10 pcs. M16x80, 12.9 quality UNBRAKO.Tightening torque: 260.

Refit the washer and the 10 attachmentscrews that hold the parallel arm to thegearbox unit.

6

Reused screws may be used, providingthey are lubricated as detailed in sectionScrew Joints in the Product manual, ref-erence information, before fitting.

Detailed in section Refitting, tie rod onpage 188

Move the upper arm to a horizontal pos-ition with a crane (if not already posi-tioned horizontal) and refit the tie rod.

7

xx0300000127

Reposition the cabling and tighten thecable attachment screws.

8




DANGER

Make sure all safety requirements aremet when performing the first test run.These are further detailed in the sectionDANGER - First test run may cause in-jury or damage! on page 46.

10



Continued

4.6 Frame and base

4.6.1 Replacement of balancing device

Location of balancing deviceThe balancing device is located as shown in the figure below. (The figure showsthe IRB 4400.)A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000100

Balancing deviceA

BracketB

Attachment screws, bracket (M12x50)C

Press out holeD

Front screwsE

ForkF

End part of shaftG



4 Repair4.6.1 Replacement of balancing device

Required equipment


Includes balancing device3HAC3702-1

3HAC15083-1Balancing deviceIRB 4400

Includes cylindrical rollerbearing 3HAC4334-2Includes front screws3HAC6456-1

3HAB3701-26Sealing ring with dustlip

Used to lubricate:• the bearings at the

balancing devicebrackets (min. 500ml. in each bearing)

• the sealing at the bal-ancing device brack-ets

• the bearing at thebalancing device fork

3HAC3537-1Grease

Used to lubricate the bear-ing at hte balancing devicefork.

Nipple

The lubrication hole is di-mensioned M10.

The contents are defined insection Standard tools onpage 277.


M10x40HSecuring front screwsH= threaded to the head.Used to unload the balan-cing device before removal.

Used to fit the cylindricalroller bearings and the seal-ings into the brackets.

3HAC5465-1Press tool, bearing



Removal, balancing deviceThe procedure below details how to remove the balancing device.


WARNING

Do not under any circumstances, deal withthe balancing device in any other way thanthat detailed in the product documentation!For example, attempting to open the balan-cing device is potentially lethal!

1




Continued


DANGER



2

CAUTION

The balancing device weighs 50 kg.All lifting accessories used must be sizedaccordingly!

3

xx0300000088

Move the manipulator to the calibration pos-ition, as shown in the figure to the right.

4

• A: Approximately 2º




Continued


xx0300000089

Remove the two securing screws (A), loc-ated at the fork of the balancing device.Also remove the plate (C) which securesthat the bushing (D) is held in position.

5

The fork is shown in the figure Location ofbalancing device on page 194.

xx0300000095

Unload the balancing device by replacingthe two front screws (A) with two securingfront screws.Unload the device level by fastening thesecuring screws parallel with each other.

6

Dimension specified in Required equip-ment on page 195!

Check that the piston is unloaded by movingit manually.

7




Continued


Shown in the figure Location of balancingdevice on page 194!

xx0300000098

Remove the four attachment screws, bracketfrom the bracket at the right side of the bal-ancing device (A), seen from above.

8

Shown in the figure Location of balancingdevice on page 194!

Remove the bracket from the frame bypressing it out using a M10x30 screw in thepress out hole.

9

xx0300000099

Remove the balancing device by pushing itto the side.Note!The balancing device weighs 50 kg!

10

If the balancing device is to be replaced witha new device, the bracket on the right sidemust be removed and fitted to the newdevice.

11




Continued

Refitting of balancing deviceThe procedure below details how to refit the balancing device.


WARNING

Do not under any circumstances, deal with thebalancing device in any other way than thatdetailed in the product documentation! Forexample, attempting to open the balancingdevice is potentially lethal!

1

DANGER



2

CAUTION

The balancing device weighs 50 kg.All lifting accessories used must be sized ac-cordingly!

3

The procedure is detailed in Fitting ofcylindrical roller bearing on page 201

Fit the cylindrical roller bearings and sealingsto the balancing device and brackets if

• the balancing device is a new sparepart

• the old bearings/sealings are damaged.

4


If the balancing device is a new sparepart, it must be unloaded as describedinRemoval, balancingdevice onpage195

Lift the balancing device to its mounting posi-tion.

5

Shown in the figure Location of balan-cing device on page 194

Fit the balancing device to the left bracket andput the fork into correct position.

6

4 pcs: M12x50, tightening torque: 82 NmRefit the right bracket with attachment screws,bracket .

7Shown in the figure Location of balan-cing device on page 194

2 pcs. MC6S M10x12 8.8 fzb.Refit the original protection screws in the pressout holes in both the brackets.

8Shown in the figure Location of balan-cing device on page 194




Continued


xx0300000089

Lubricate the bearing at the fork:• Remove the two stop screws (B).• Fill with grease through one of the lub-

rication holes, until excessive grease isforced out through the second hole. Usea nipple!

• Refit the two stop screws.• Refit the plate with one screw M8x16

(C). This plate secures the bushing (D)is held in its position.

9

A: Securing screws (2 pcs)B: Stop screws, M10 x 40 (2 pcs)C: Plate and screw M8 x 16 (1 pc)D: Bushing

The fork is shown in the figure Locationof balancing device on page 194

Before restoring the balancing device, checkthat:

• the fork is in position• the fork does not cover the lubrication

holes of the shaft!

10

xx0300000095

Restore the balancing device by removing thereplacement front screws (A) and refitting theoriginal protection front screws.

11

2 pcs: MC6S M10x12 8.8 fzb

Shown in the figure above in Refitting ofbalancing device on page 199

Refit the fork to the shaft in the lower arm, byrefitting the two securing screws (A) at the forkof the balancing device.

12

Make sure that the fork does not cover thelubrication holes of the shaft!




Continued


DANGER

Make sure all safety requirements are metwhen performing the first test run. These arefurther detailed in the section DANGER - Firsttest run may cause injury or damage! onpage 46.

13

Fitting of cylindrical roller bearingThe procedure below details how to fit the cylindrical roller bearings onto thebalancing device shaft and into the frame brackets.


Shown in the figure Locationof balancing device onpage 194

Fit the inner ring of the bearing onto both end parts ofthe balancing devices shaft.

1

Art. no. is specified in Re-quired equipment on page195

Fit the outer ring of the bearing into both brackets witha press toll, bearing.

2


Fit the sealing ring with dust lip with the same, butturned, press tool, bearing.

3

Art. no. and amount specifiedin Required equipment onpage 195

Lubricate the bearing and the sealing with grease.4

DANGER

Make sure all safety requirements are met when perform-ing the first test run. These are further detailed in thesection DANGER - First test run may cause injury ordamage! on page 46.

5



Continued

4.6.2 Replacement of serial measurement unit

WARNING

See instructions for batteries,WARNING - Safety risks during handling of batterieson page 51.

Location of serial measurement unitThe serial measurement unit is located inside the base of the robot, behind therear cover, as shown in the figure below.

xx0300000106

Rear cover plateA

Different versions, serial measurement unit

Note

There are different variants of SMB units and batteries. The variant with the3-pole battery contact has longer lifetime for the battery.It is important that the SMB unit uses the correct battery. Make sure to order thecorrect spare parts. Do not replace the battery contact!



4 Repair4.6.2 Replacement of serial measurement unit

xx0300000105

Different versions of serial measurement unit1 and 2

New version of serial measurement unit(2)

R2.SMBA

R2.FB4-6B

R2.FB1-3C

Fastening plateD

Battery packE

Required equipment

NoteEquipment, etc.

Serial measurement unit on page 288Serial measurement unit

Serial measurement unit on page 288Fastening plate

Content is defined in section Standard toolson page 277.

Standard toolkit


Other tools and procedures may be re-quired. See references to these proceduresin the step-by-step instructions below.

See chapter Circuit diagram on page 301.Circuit Diagram

Removal, serial measurement unitThe procedure below details how to remove the serial measurement unit.


DANGER



1




Continued


ELECTROSTATIC DISCHARGE (ESD)


2

Shown in the figure Locationof serial measurement uniton page 202.

Remove the rear cover plate from the base.3

Cut all the straps.4

Unscrew the nuts that attaches the serial measure-ment unit inside the base.

5


The connectors are shownin the figure Different ver-sions, serial measurementunit on page 202.

Remove the connectors from the board.7

Refitting, serial measurement unitThe procedure below details how to refit the complete serial measurement unit.


DANGER



1



2

Art. no. is specified in Re-quired equipment onpage 203.

Refit the connectors to the serial measurement unit.3

The connectors are shownin the figure Different ver-sions, serial measurementunit on page 202.

Refit the serial measurement unit inside the baseusing nuts.

4

Strap the cables.5

Shown in the figure Locationof serial measurement uniton page 202.

Refit the rear cover plate on the base.6




Continued







Continued

4.6.3 Replacement of pushbutton unit for brake release

Location of pushbutton unitThe pushbutton unit for brake release is located in the base of the robot, as shownin the figure below. (The figure shows the IRB 4400.)A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000106

Rear cover plateA

Connectors on pushbutton unitThe connectors X8, X9 and X10 are placed on the pushbutton unit as shown in thefigure below.

xx0300000201

Required equipment


3HAC0017-1Pushbutton unit


3HAC17594-1

Standard toolkit



Art. no. is specified in sectionon page ? in part 2 of theProduct manual.




4 Repair4.6.3 Replacement of pushbutton unit for brake release

Removal, pushbutton unitThe procedure below details how to remove the pushbutton unit from the robot.


DANGER



1



2

Secure the robot by moving...• the lower arm to one of its end positions• the upper arm to its end position.

3

Shown in the figure Locationof pushbutton unit onpage 206.


Shown in the figureConnect-ors on pushbutton unit onpage 206.

Remove the connectors X8, X9 and X10 from thepushbutton unit.

5

Remove the pushbutton unit by removing its attach-ment screws.

6

Refitting of pushbutton unitThe procedure below details how to refit the pushbutton unit to the robot.


DANGER



1



2


Refit the new pushbutton unit with its attachmentscrews.

3




Continued


Shown in the figureConnect-ors on pushbutton unit onpage 206.

Refit the connectors X8, X9 and X10 to the pushbut-ton unit.

4

Shown in the figure Locationof pushbutton unit onpage 206.

Refit the rear cover plate to the base of the robot.5

Calibration is detailed insection Calibration onpage 253.


DANGER


7



Continued

4.6.4 Replacement of mechanical stop pin, axis 1

Location of mechanical stop pinThe mechanical stop pin on axis 1 is located on the frame as shown in the figurebelow. (The figure shows the IRB 4400.)A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000182

Mechanical stop pin, axis 1A

Set screwB

Required equipment




3HAC17594-1

Standard toolkit



Replacement, mechanical stop pinThe procedure below details how to replace the mechanical stop pin on axis 1.

WARNING




4 Repair4.6.4 Replacement of mechanical stop pin, axis 1


DANGER



1

Shown in the figure in Loca-tion of mechanical stop pinon page 209.

Remove the set screw.2

Shown in the figure in Loca-tion of mechanical stop pinon page 209.

Remove the old mechanical stop pin.3


Refit the new mechanical stop with the set screw.4

M10x12


4 Repair4.6.4 Replacement of mechanical stop pin, axis 1

Continued

4.7 Motors

4.7.1 Replacement of motor, axis 1

Location of motorThe motor, axis 1, is located as shown in the figure below. (The figure shows theIRB 4400.)The motor and the drive gear constitute one unit.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000154

Motor, axis 1A

Connection box with coverB

Attachment screws and washersC

Required equipment


Elmo3HAC5952-1Motor unit, axis 1Includes motor pinion.(IRB 4400)

Yaskawa3HAC021724-001Motor unit, axis 1Includes pinion(IRB 4400)

21520431-11O-ring, motor


Between the motor and theconnection box.

3HAC4432-1Gasket

Replace if damaged!



4 Repair4.7.1 Replacement of motor, axis 1




24 VDC, 1.5 APower supplyUsed in order to release thebrakes.

Choose one of the tools.3HAB7887-1 or3HAB1408-1

Measuring tool



See chapter Circuit diagramon page 301.

Circuit Diagram


Calibration PendulumInstruction

Removal, motor axis 1The procedure below details how to remove the motor, axis 1.

DANGER

If a shelf-mounted robot version is not flat mounted, the manipulator can containa living force!Removing the motor from axis 1 may result in movement of the axis, becausethe brake is released.To avoid this, move the robot into normal calibration position or move axis 1 toget the lowest location of the center of gravity for the upper arm.

InfoAction

DANGER



1

CAUTION


2

Shown in the figure Location of mo-tor on page 211.

Remove the cover of the connection box.3




Continued

InfoAction

Disconnect all the connectors in the motor.4


Remove the connection box.5


Remove the attachment screws and washersof the motor.

Note

Check the position of the motor label beforeremoving the motor! The motor must bemounted back at the same position!

6

Remove the motor.7

Refitting, motor axis 1The procedure below details how to refit the motor, axis 1.

InfoAction

DANGER



1

CAUTION


2

Note

The motor units from Elmo and Yaskawa arenot compatible!

3

Check that the assembly surfaces are cleanfrom paint, lubricant etc.

4

Make sure that the motor and the gearbox arenot damaged or scratched.

Part no. is specified in Requiredequipment on page 211

Fit the o-ring to the new motor unit.5

Connect to connector R3.MP1• +24V: pin 7• 0V: pin 8.

Release the brake of the motor by connectingthe 24 VDC power supply.

6

Art. no. is specified in Requiredequipment on page 211

Apply flange sealing to the motor flange.7




Continued

InfoAction

Place the new motor in the gearbox.8Do not damage the pinion and the gear-wheel!Note the position of the motor! The motor labelshould be mounted in the same position as ithad before removal.

xx0300000155

Fit the upper and lower screws (A, B) andtighten until there is no space between themotor flange and the gearbox.There should be a big backlash between themotor pinion and the gear.

9

A: Lower screwB: Upper screwC: Pushing direction

Adjustment detailed in section Ad-justment of motors, axes 1-3 onpage 224

Note

Adjust the motor before continuing the refittingprocedure!

10

Total 4 pcs. M10x30.Fit the other two attachment screws and wash-ers.

11Tightening torque: 60 Nm.

Detailed in section Inspection of oillevels on page 116

Check the oil level. Fill with oil if necessary12


Refit the connection box.Replace the gaskets if they are damaged!

13

Reconnect all the connectors.14

Refit the cover of the connection box.15

Calibration is detailed in a separatecalibration manual enclosed withthe calibration tools.






Continued

InfoAction

DANGER


17



Continued



xx0300000159

Motor, axis 2A

Connection boxB

Attachment screws and washersC

Required equipment


Elmo3HAC5954-1Motor unit, axis 2Includes pinion(IRB 4400)


21520431-11O-ring








24 VDC, 1,5 APower supplyUsed in order to release thebrakes.

Choose one of the two tools.3HAB7887-1Measuring tool3HAB1408-1




Circuit Diagram




InfoAction

DANGER



1

xx0200000022

2

Secure the arm system before removing the motor!The brake is located in the motor and is thereforereleased when the motor is removed.

CAUTION

Whenever parting/mating motor and gearbox, thegears may be damaged if excessive force is used!

3



Shown in the figure Location ofmotor on page 216.


Note

Check the position of the motor label before removingit. The motor must be mounted in the same position.

7




Continued

InfoAction


Remove the attachment screws and washers of themotor.

Note

Oil will start to run out when removing the motor!

8

Remove the motor.9


InfoAction

DANGER



1

CAUTION


2

Note

The motor units from Elmo and Yaskawa arenot compatible!

3


4

Make sure that the motor and the gearboxare not damaged or scratched.


Mount the o-ring to the new motor unit.5

Connect to connector R3.MP2• +24V: pin 7• 0V: pin 8


6

Art. no. is specified in Required equip-ment on page 216


Place the new motor in the gearbox.8Do not damage the pinion or the gear wheel!

Note

Check the position of the motor! The motorlabel should be mounted in the same positionas it had before the removal.




Continued

InfoAction

xx0300000160


9

A: Upper screwB: Lower screwC: Pushing direction

Adjustment is detailed in sectionAdjust-ment of motors, axes 1-3 on page 224Note

Adjust the motor before continuing the refit-ting procedure!

10

Shown in the figure Location of motoron page 216

Fit the other two attachment screws andwashers.

11

2 pcs: M10x702 pcs: M10x30Tightening torque: 60 Nm

Where to find type of oil and totalamount is detailed in Type and amountof oil in gearboxes on page 115.

Refill with oil.12

Shown in the figure Location of motoron page 216


Reconnect the connectors.14


Calibration is detailed in a separate cal-ibration manual enclosed with the calib-ration tools.


General calibration information is in-cluded in section Calibration onpage 253.

DANGER


17



Continued



xx0300000163

Motor, axis 3A

Connection boxB

Attachment screws and washers, motorC

Required equipment


Elmo3HAC5954-1Motor unit, axis 3Includes pinion(IRB 4400)


21520431-11O-ring








24 VDC, 1.5 APower supplyTo be used for releasingthe brakes.

Choose one of the twotools.

3HAB7887-13HAB1408-1

Measuring tool




Circuit Diagram

General calibration inform-ation is included in sectionCalibration on page 253.



InfoAction

DANGER



1

DANGER

Secure the upper arm system before removing themotor from axis 3! The brake is located in the motorand is therefore released when the motor is removed.

2

CAUTION

Whenever parting/mating motor and gearbox, the gearsmay be damaged if excessive force is used!

3

Remove the cover from the connection box.4



Remove the connection box from the motor.6

Note

Check the position of the motor label before removingit! The motor must be mounted in the same position.

7




Continued

InfoAction


Remove the attachment screws and washers, motor.

Note

Oil will start to run out when removing the motor!

8

Remove the motor.9

Refitting motor axis 3The procedure below details how to refit the motor, axis 3.

InfoAction

DANGER



1

CAUTION


2

Note

The motor units from ELMO and YASKAWAare not compatible!

3


4




Connect to connectorR3.MP3• +24V: pin 7• 0V: pin 8


6

Art. no. is specified inRequired equipmenton page 220


Note

Check the position of the motor! The motorlabel should be mounted in the same pos-ition as it had before the removal.

Place the new motor in the gearbox.Do not damage the pinion and the gearwheel!

8




Continued

InfoAction

xx0300000160


9

Motor axis 2, is shown in the figure!A: Upper screwB: Lower screwC: Pushing direction

Adjustment is detailed in section Adjust-ment of motors, axes 1-3 on page 224Note

Adjust the motor before continuing the refit-ting procedure!

10

Shown in figure Location of motor onpage 220

Fit the other two attachment screws andwashers, motor.

11

M10x70M10x30Tightening torque: 60 Nm

Where to find type of oil and total amountis detailed in Type and amount of oil ingearboxes on page 115.

Refill with oil.12

Shown in the figure Location of motor onpage 220


Reconnect the connectors.14


Calibration is detailed in a separate calib-ration manual enclosed with the calibrationtools.



DANGER

Make sure all safety requirements are metwhen performing the first test run. These arefurther detailed in the section DANGER -First test run may cause injury or damage!on page 46.

17



Continued

4.7.4 Adjustment of motors, axes 1-3

GeneralThis section details how to adjust the motors during refitting. It applies to the motorsin axes 1, 2 and 3 and is a complement to the refitting instructions found in sections

• Replacement of motor, axis 1 on page 211• Replacement of motor, axis 2 on page 216• Replacement of motor, axis 3 on page 220.

Required equipment


Content is defined in section Standardtools on page 277.


Choose one of the tools. They are allcompatible with the motor.

Either3HAB7887-1 or

Measuring tool

3HAB1408-1

24 VDC, 1.5 APower supplyFor releasing the brakes.




Circuit Diagram

AdjustmentThe procedure below details how to adjust the motors during refitting.

InfoAction

Lock the motor brake before mounting theadjustment tool.

1


Fit the measuring tool to the motor axis.2

Axis 1 motor: connect to connectorR3.MP1

• +24V: pin 7• 0V: pin 8.


• +24V: pin 7• 0V: pin 8.


• +24V: pin 7• 0V: pin 8.

Release the brake of the current motor byconnecting the 24VDC supply.

3



4 Repair4.7.4 Adjustment of motors, axes 1-3

InfoAction

Rotate the motor shaft with the measuringtool. Measure the torque in both directionswith a spring balance.

4

A normal torque is 0.6-0.8 Nm (=6-8 N on ra-dius 100 mm). Torques higher than 0.8 Nmare not allowed, as they will reduce the life-time of the motor and gear.

Note

The brake must be released in the mo-tor.

Loosen the lower and upper screws until themotor can be moved sideways by hand.

5

Push the motor with one hand against thegear and tighten the two screws with theother hand.

6

1)The brake disc is mounted on themotor shaft with a type of splinedcoupling. Between the splines there isa narrow backlash.

Note

There should always be a backlash, butit should be as minimal as possible.

Measure the torque with the motor shaft indifferent positions. The torque should be max.0.1 Nm (on radius 50 mm) more than meas-ured before.If the torque is more,

• slightly loosen the screws a little andcarefully knock the motor in the oppos-ite direction

• then measure the torque again.Check that the backlash is very limited, bymoving the tool back and forward in smallmovements.

7

When turning the motor shaft, a tick-tacksound can be heard from the brake disc1) .This should not be mixed up with the back-lash. The difficult part is to find the motorposition where the torque just starts to in-crease.

Remove the measuring tool.8

Disconnect the brake release voltage.9

Refitting, motor axis 1 on page 213Continue refitting the motor.10Refitting, motor axis 2 on page 218Refitting motor axis 3 on page 222


4 Repair4.7.4 Adjustment of motors, axes 1-3

Continued

4.7.5 Removal of motor, axes 4, 5 and 6

Location of motorsThe motors, axes 4, 5 and 6, are located as shown in the figure below. (The figureshows the IRB 4400.)The motor and the drive gear of each axis constitute one unit.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000164

Motor unit, axis 4A

Motor unit, axis 5B

Motor unit, axis 6C

Attachment screws and washers, motorD

Connection boxE

Required equipment


Content is defined in section Stand-ard tools on page 277.





Circuit Diagram



4 Repair4.7.5 Removal of motor, axes 4, 5 and 6

Removal, motor axes 4, 5 and 6The procedure below details how to remove the motors of axes 4, 5 and 6.

InfoAction

DANGER



1

DANGER

Secure the arm system before removing any motor!The brake is located in the motor and is therefore re-leased when the motor is removed!

2

CAUTION

Whenever parting/mating motor and gearbox, the gearsmay be damaged if excessive force is used!

3

Draining is detailed in sections:• Oil change, gearbox axis

4 on page 119.• Oil change, gearbox axis

5 and 6 (all robot ver-sions) on page 122

Drain the oil from the gearbox.4


Disconnect all the connectors in the connection box.6

Shown in the figure Location ofmotors on page 226.


Note

Check the position of the motor before removing it.The motor must be mounted back at the same position.

8

Shown in the figure Location ofmotors on page 226.

Remove the attachment screws and washers, motor.9

Remove the motor.10


4 Repair4.7.5 Removal of motor, axes 4, 5 and 6

Continued

4.7.6 Refitting of motor, axis 4

Location of motorThe motors, axes 4, 5 and 6, are located as shown in the figure below. (The figureshows the IRB 4400.)The motor and the drive gear of each axis constitute one unit.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000164

Motor unit, axis 4A

Motor unit, axis 5B

Motor unit axis 6C


Connection boxE

Required equipment


Elmo3HAC10603-1Motor unit, axis 4Includes pinion.(IRB 4400)


21522012-426O-ring



4 Repair4.7.6 Refitting of motor, axis 4


3 pcs3HAB3676-1GasketBetween the motors andthe connection box.Replace if damaged.

Content is defined insection Standard toolson page 277.


3HAB1409-1Measuring tool

24VDC, 1.5APower supplyUsed to release thebrake of the motor.

These procedures in-clude references to thetools required.



Circuit Diagram

Art. no. is specified insection Calibration onpage 253 manual.



InfoAction

DANGER



1

CAUTION


2

Note

The motor unit from ELMO and YASKAWAare not compatible!

3


4





Continued

InfoAction




Fit themeasuring tool to the rear of the motor.6

Connect to connector R3.MP4• +24V: pin 7• 0V: pin 8.


7

Place the new motor unit in the gearbox.Do not damage the pinion or the gear wheel.

8

Find the position with the least play by turningthe motor shaft 10 revolutions, notingchanges in play as you turn the motor.

9

Push the motor in a radial direction so thatthe play is minimal within one motor revolu-tion without the gear "chewing".

10

Shown in the figure Location of motoron page 228.

Refit the motor with its attachment screwsand washers, motor.

11

4 pcs, M6x25. Tightening torque: 15 Nm.

Detailed in section Oil change, gearboxaxis 4 on page 119.

Refill with oil, if drained.12


Check the position of the three gaskets, loc-ated between the motors and the connectionbox. Replace them if damaged.

13

Shown in the figure Location of motoron page 228.

Refit the connection box.Make sure the gaskets are seated properly!

14


Refit the cover to the connection box.16




DANGER


18



Continued


Location of motorThe motors, axes 4, 5 and 6 are located as shown in the figure below. (The figureshows the IRB 4400.)The motor and drive gear of each axis constitutes one unit.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000164

Motor unit, axis 4A

Motor unit, axis 5B

Motor unit, axis 6C


Connection boxE

Required equipment




21522012-426O-ring





3 pcs3HAB3676-1GasketBetween the motor and theconnection box.Replace if damaged.




24VDC, 1.5APower supply2 pcs, used to release thebrakes in the motors for axes4 and 5.




Circuit Diagram


Calibration PendulumInstruction

Refitting, motor axis 5The procedure below details how to refit the axis 5 motor.

InfoAction

DANGER



1

CAUTION


2

Note

The motor units from ELMO and YASKAWA arenot compatible!

3

Check that the assembly surfaces are clean frompaint, lubricant etc.

4

Make sure that the motor and the gearbox are notdamaged or scratched.


Fit the o-ring into the new motor.5




Continued

InfoAction


Fit the measuring tool to the rear of the motor.6

Connect to connectorR3.MP4/MP5

• +24V: pin 7• 0V: pin 8.

Release the brakes in the motors for axes 4 and5, by connecting the 24 VDC power supply.

7

Place the new motor unit in the gearbox.Do not damage the pinion or the gear wheel.

8

Find the position of least play by turning the out-going shaft for axis 4 in intervals of 90°, one re-volution in all, to locate the area where the playfor the motor axis 5 is the smallest.

9

Turn the motor for axis 5 one full revolution at atime, five revolutions in all. Find the smallest playwithin this range.

10

Push the motor in a radial direction so that theplay is minimal within one motor revolution withoutthe gear "chewing".

11


Refit the motor with its attachment screws andwashers, motor.

12

4 pcs, M6x25. Tightening torque:15 Nm.

Detailed in section:• Oil change, gearbox axis 5

and 6 (all robot versions) onpage 122.



Check the position of the three gaskets, locatedbetween the motors and the connection box. Re-place them if damaged.

14



15


Refit the cover on the connection box.17

Calibration is detailed in a separ-ate calibration manual enclosedwith the calibration tools.



DANGER


19



Continued


Location of motorThe motors, axes 4, 5 and 6, are located as shown in the figure below. (The figureshows the IRB 4400.)The motor and the drive gear of each axis constitute one unit.A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000164

Motor unit, axis 4A

Motor unit, axis 5B

Motor unit, axis 6C


Connection boxE

Required equipment




21522012-426O-ring





3 pcs3HAB3676-1GasketBetween the motors andthe connection box.Replace if damaged.




24VDC, 1.5APower supply3 pcs, used to release thebrakes in the motors foraxes 4, 5 and 6.


Other tools and proced-ures may be required. Seereferences to these proced-ures in the step-by-stepinstructions below.


Circuit Diagram

Art. no. is specified insection Calibration onpage 253.


Refitting, motor axis 6The procedure below details how to refit the axis 6 motor.

InfoAction

DANGER



1

CAUTION


2

Note

The motor units from ELMO and YASKAWA are notcompatible!

3

Check that the assembly surfaces are clean frompaint, lubricant etc.

4

Make sure that the motor and the gearbox are notdamaged or scratched.

Part no. is specified inRequiredequipment on page 234.





Continued

InfoAction

Art. no. is specified inRequiredequipment on page 234.

Fit the measuring tool at the rear of the motor.6

Connect to connectorR3.MP4/MP5/MP6

• +24V: pin 7• 0V: pin 8.

Release the brakes in the motors for axes 4, 5 and6, by connecting the 24 VDC power supply.

7

Place the new motor unit in the gearbox.Do not damage the pinion or the gear wheel!

8

Find the position of least play by turning the outgoingshaft for axis 4 in intervals of 90°, one revolution inall, to locate the area where the play for the axis 6motor is the smallest.

9

Turn the motor for axis 5 one full revolution at a time,five revolutions in all. Find the least play for axis 6within this range.

10

Turn the motor for axis 6 one full revolutipon at atime, three turns in all. Find the least play for axis 6within this range.

11

Push the motor in a radial direction so that the playis minimal within one motor revolution without thegear "chewing".

12


Refit the motor with its attachment screws andwashers, motor.

13

4 pcs, M6 x 25. Tighteningtorque: 15 Nm.

Detailed in section• Oil change, gearbox axis

5 and 6 (all robot ver-sions) on page 122.


Part no. is specified inRequiredequipment on page 234.

Check the position of the three gaskets, locatedbetween the motors and the connection box. Replacethem if damaged.

15



16


Refit the cover on the connection box.18

Calibration is detailed in a sep-arate calibration manual en-closed with the calibration tools.



DANGER


20



Continued

4.8 Gearboxes

4.8.1 Replacement of gearbox unit, axes 1-2-3

GeneralThe gearboxes of axes 1-2-3 are handled as one complete unit. Except for thegearboxes, the spare part also includes motor units and lubricating oil for the axes1, 2 and 3.

Location of gearbox unitThe gearbox unit, axes 1-2-3, is shown in the figure below. (The figure shows theIRB 4400.)A more detailed view of the component and its position may be found in chapterExploded views on page 291.

xx0300000174

Gearbox unit axes 1-3, spare partA

Bottom plateB

Attachment screws and washers, gearbox unitC

SealingD

Required equipment


Does not include motors andlubricating oil.

3HAC5948-1Gearbox unit, axes 1-3(IRB 4400)

Replace if damaged!3HAC5479-2Sealing


3HAC17594-1

Standard toolkit



4 Repair4.8.1 Replacement of gearbox unit, axes 1-2-3


Lifting capacity: 500 kg.Lifting slings with hoistingblock




Calibration Pendulum in-struction

Removal, gearbox unitThe procedure below details how to remove the gearbox unit, axis 1-2-3, includingthe motors, from the robot.


DANGER



1

CAUTION

The robot arm system weighs 245 kg.All lifting accessories used must besized accordingly!

2

CAUTION

The robot base weighs 130 kg.All lifting accessories used must besized accordingly!

3

Detailed in sectionsReplacement of cableharness, axes 1-3 on page 143, and Re-placement of serial measurement unit onpage 202.

Remove the cable harness and serialmeasuring board.

4

Detailed in sectionReplacement of tie rodon page 186.


Detailed in sectionReplacement of paral-lel arm / Replacement of bearing onpage 190.


Detailed in section Replacement of com-plete arm system on page 154.

Remove the complete arm system.7

Unfasten the robot from the foundation.8




Continued

Info/IllustrationActionThis figure shows the IRB 4400.

xx0300000172

Fit and secure straps (A) around the rearpart of the gearbox unit, as shown in thefigure to the right. Attach the straps tolifting slings with a hoisting block.Fit and secure hooks to the lifting lugs(B).Use the same crane for both attachmentpoints.

9

Lift the gearbox unit together with thebase and use the hoisting block to tipthe complete assembly forward 90°.

10

xx0300000173

Place the assembly on a level surfaceand support it at position A, accordingto the figure on the right.

CAUTION

Make sure the unit is stable and restssecurily before removing the liftingequipment.

11

• B: Approximately 200 mm (IRB4400 all models)

Shown in the figure Refitting, completearm system on page 156.

Remove the bottom plate from the base.12

Move the lifting straps to the base andunload its weight.

13

Shown in the figureRefitting, cabling axes1-3 on page 146.

Remove the attachment screws andwashers, gearbox unit.

14

Remove the base from the gearbox unit.15

Remove the sealing from the gearboxunit.

16




Continued

Refitting, gearbox unitThe procedure below details how to refit the gearbox unit, including motors, to therobot.


DANGER



1

CAUTION

The robot base weighs 130 kg.All lifting accessories used must be sizedaccordingly!

2

CAUTION


3

xx0300000173

Place the new gearbox unit on a level sur-face and support it at position A, accordingto the figure on the right.Make sure the unit is stable and rests secur-ily on the surface, including the weight ofthe base that is to be refitted.

4

Part no. is specified in Requiredequipment on page 237B: Approximately 200mm (IRB 4400models)

Shown in figure Location of gearboxunit on page 237

Refit the sealing to the gearbox unit.Replace it if damaged.

5





Continued


Raise the base and fit it to the gearbox unit.6Align the hole pattern of the base to thegearboxes. Turn the gear if necessary bythe motor pinion, axis 1.

Shown in figure Location of gearboxunit on page 237

Refit the base with the attachment screwsand washers, gearbox unit.

7

Attachment: 14 pcs, M16x80-12.9UNBRAKO.Tightening torque: 260 Nm.Reused screws may be used, provid-ing they are lubricated as detailed inScrew joints in the Product manual,reference information before fitting.

Shown in the figure Location of gear-box unit on page 237

Refit the bottom plate with its attachmentscrews.

8

See sectionRemoval, gearbox unit onpage 238

Strap the gearbox unit as in the removal in-struction

9

Lift the gearbox unit together with the baseand use the hoisting block to tip the com-plete assembly backward by 90°, into nor-mal mounting position.

10

Refit the robot to the foundation.11

Detailed in section Replacement ofcomplete arm system on page 154

Refit the complete arm system.12

Detailed in section Refitting, parallelarm/bearing on page 192


Detailed in sectionRefitting, tie rod onpage 188


Detailed in sections Refitting, cablingaxes 1-3 on page 146

Refit the cable harness and serial measur-ing board.

15




DANGER

Make sure all safety requirements are metwhen performing the first test run. Theseare further detailed in the section DANGER- First test run may cause injury or damage!on page 46.

17



Continued

4.8.2 Adjusting play on axis 4, intermediate gear

Illustration, adjusting playIn order to adjust the play on axis 4, the gear must be accessible. The figure belowshows the parts in the upper arm housing that must be removed/unlocked.

xx0300000191

CoverA

Attachment screws, coverB

Screws, 3 pcsC

Required equipment


Loctite 57412340011-116

Flange sealing


3HAC17594-1

Standard toolkit





4 Repair4.8.2 Adjusting play on axis 4, intermediate gear

Adjusting play, axis 4The procedure below details how to adjust the play for the intermediate gear ofaxis 4.


DANGER



1

Detailed in section Removal of motor,axes 4, 5 and 6 on page 226.

Remove the motors for axes 4, 5 and 6.2

Shown in the figure Illustration, adjust-ing play on page 242.

Remove the cover.3

Shown in the figure Illustration, adjust-ing play on page 242.

Unlock the three screws.4

Rotate axis 4 to find the highest position ofthe gear on the upper arm tubular.

5

3 pcs, tightening torque: 69 Nm.Tighten the three screws again.6


Apply flange sealing to the cover and refitit with its attachment screws and washers.

7

10 pcs: M8x40. Tightening torque: 24Nm.


4 Repair4.8.2 Adjusting play on axis 4, intermediate gear

Continued

4.9 Additional repair routines for Foundry Prime

4.9.1 Repair routines

OverviewRobots working with water jet cleaning have special tightness for water jet cleaningapplication and require special repair routines to maintain the tightness level. Therepair must be done according to the repair chapter with the additions describedin the following procedures.

Required equipmentFollow the instruction in the Repair chapter, with the following additional measure.

Article numberEquipment

21662055-3Cable strap


Drill diameter 8.8 mm

Replacement of motor axes 1-3The following procedure details how to replace motors axes 1-3.

NoteAction

xx0600003111

Apply Sikaflex 521FC on bothsides of the gasket between motorand cable box before assemblingthe cable box.

1

• A: Sikaflex• B: Gasket

Cut the projecting part of the gas-ket with a knife.

2



4 Repair4.9.1 Repair routines

NoteAction

xx0600003112

Apply Sikaflex 521FC outside thegasket and the cover plate aroundthe motor.

3

• A: Sikaflex

xx0600003113

Apply Sikaflex 521FC underneaththe cover attachment screw heads.

4

• A: Sikaflex




Continued

Replacement of cable harness to motor axes 1-3 and 4-6The following procedure details how to replace motor cabling axes 1-3 and 4-6.

NoteAction

Cable box, motor unit axes 1-3

xx0600003114

Drill and tap holes in the cable boxes for theair fittings before assembling a new cableharness.Drill diameter: 8.8mmThread: 1/8" pipe thread

1

• A: Air connection on motor cablebox axis 1.

• B: Air connection on motor cablebox axis 2 and 3 (not used earthconnection.

Cable box, motor unit axes 4-6

Additional r

• A: Air connection on motor cablebox axis 4-6




Continued

Replacement of balancing deviceThe following procedure details how to replace the balancing device.

NoteAction

xx0600003123

Before refitting the balancing device in therobot, apply Mercasol on both side of the earand both side of the washers.

1

• A: Mercasol

Replacement of air hose (Required equipment)

1

3

4

5

2

7

6

xx0600003342




Continued

Article numberEquipment

Pos 6 in figure above3HAC026511-001/ 1Elbow fitting

3HAC026523-001Rubber clamp

Pos 3 in figure above3HAC026515-001/ 2T-plug connector

Pos 2 in figure above3HAC026514-001/ 3Y-plug connector

Pos 1 in figure above3HAC026513-001/ 1Bulkhead plug connector

According to table: Pneumatichouse Length 7500 mm

3HAC026526-001Air hose

Pos 4 in figure above3HAC026516-001/ 1Straight plug connector

Pos 5 in figure above3HAC026507-001/ 4Straight fitting

Pos 7 in figure above3HAC027569-001/ 1Adapter

xx0600003343

NoteArticle number3HAC026526-001

Pneumatic house

From the Bulkhead plug in the front plate to theT-plug connector for the SMB box, se step 1 and2 in Replacement of air hose on page 249

140 mmA

From the T-plug connector to the stright plugconnector in the SMB box.

270 mmB

From the T-plug connector through the base andup to the Y-plug connector at the motors of axis4,5,6, se step 3-5 in Replacement of air hose onpage 249.

3050 mmC

From the Y-plug connector at axis 4,5,6 motorsto the straight fitting in the motor cover axis 4,5,6.

40 mmD

From the Y-plug connector at axis 4,5,6 motorsto the the Y-plug connector at for the motors ofaxis 3, se step 6 in Replacement of air hose onpage 249.

1750 mmE

From the Y-plug connector at axis 3 motors to thestraight fitting in the motor cover axis 3.

425 mmF




Continued

NoteArticle number3HAC026526-001

Pneumatic house

From the Y-plug connector at axis 3 to the Y-plugconnector for the balancing cylinder.

80 mmG

From the Y-plug connector for the balancing cyl-inder to the elbow fitting in the bak of the balan-cing cylinder, se step 7 inReplacement of air hoseon page 249.

460 mmH

From the Y-plug connector for the balancing cyl-inder to the T-plug connector for axis 1 and axis2.

220 mmK

From the T-plug connector to the straight fittingin the motor cover axis 1.

140 mmL

From the T-plug connector to the straight fittingin the motor cover axis 2.

365 mmM

To the Bulkhead plug in the front plate.150 mmN

Replacement of air hoseThe following procedure details how to replace the air hose.

NoteAction

Additional r

The air is let in via the cover of the rear sideof the foot where a bulkhead plug for Ø6mmplastic hose is mounted.A plastic hose is drawn from the bulkheadplug to a T-plug connector and led to theSMB compartment.

1

Additional r

The hose is drawn through a drilled hole inthe rubber sealing and firmly tightened witha straight fitting.

2




Continued

NoteAction

Additional r

In the base an extra ring of the hose is madeso that full movement for axis 1 is guaran-teed.

3

Additional r

The plastic hose is drawn from the T-plugconnector up through axis 1.A hole is drilled in the cable guide axis 1 forthe air hose. A bulkhead is mounted in thehole to prevent wear on the hose.The hose must be able to run free in thebulkhead.

4

xx0600003120

The hose continue through the lower armand is connected to a Y-plug connector atthe upper arm housing.

5




Continued

NoteAction

xx0600003121

The hose is led back down the lower arm tomotors axis 1-3 from the Y-plug connector.The air is distributed via a Y-plug connectorand a T-plug connector to the cable boxes

6

xx0600003122

xx0600003344

From the Y-plug connector for the balancingcylinder to the elbow plug in the back of thebalancing cylinder.

7



Continued

5 Calibration5.1 Introduction

GeneralThis chapter includes general information about the different calibration methodsand also the detailed procedures that do not require specific calibration equipment.When the robot system must be recalibrated, it is done according to thedocumentation enclosed with the calibration tools.

When to calibrateThe system must be calibrated if any of the following situations occur.

The resolver values are changedIf resolver values are changed, the robot must be recalibrated using the calibrationmethods supplied by ABB. Calibrate the robot carefully with standard calibration.The different methods are briefly described in the section Calibration methods onpage 254 , and further detailed in separate calibration manuals.If the robot has absolute accuracy calibration, it is also recommended, but notalways necessary to calibrate for new absolute accuracy.The resolver values will change when parts affecting the calibration position arereplaced on the robot, for example motors or parts of the transmission.

The revolution counter memory is lostIf the revolution counter memory is lost, the counters must be updated. SeeUpdating revolution counters on page 259. 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 areconnected at the first installation.

The robot is rebuiltIf the robot is rebuilt, for example, after a crash or when the reach ability of a robotis changed, it needs to be recalibrated for new resolver values.If the robot has absolute accuracy calibration, it needs to be calibrated for newabsolute accuracy.


5 Calibration5.1 Introduction

5.2 Calibration methods

OverviewThis section specifies the different types of calibration and the calibration methodsthat are supplied by ABB.

Types of calibration

Calibration methodDescriptionType ofcalibration

Calibration Pendulum(standard method)

The calibrated robot is positioned at homeposition, that is when the positions of the axes(angles) are set to 0º.

Standard calibration

orStandard calibration data is found on the SMB(serial measurement board) in the robot.

Levelmeter calibration(alternative method)

For robots with RobotWare 5.04 or older, thecalibration data is delivered in a file, calib.cfg,supplied with the robot at delivery. The fileidentifies the correct resolver/motor positioncorresponding to the robot home position.

CalibWareBased on standard calibration, and besidespositioning the robot at home position, theAbsolute accuracy calibration also com-pensates for:

• Mechanical tolerances in the robotstructure

• Deflection due to loadAbsolute accuracy calibration focuses on pos-itioning accuracy in the Cartesian coordinatesystem for the robot.

Absolute accuracycalibration (option-al)

Absolute accuracy calibration data is foundon the SMB (serial measurement board) in therobot.For robots with RobotWare 5.05 or older, theabsolute accuracy calibration data is deliveredin a file, absacc.cfg, supplied with the robot atdelivery. The file replaces the calib.cfg file andidentifies motor positions as well as absoluteaccuracy compensation parameters.A robot calibrated with absolute accuracy hasa sticker next to the identification plate of therobot.To regain 100% absolute accuracy perform-ance, the robot must be recalibrated for abso-lute accuracy!

xx0400001197



5 Calibration5.2 Calibration methods

Calibration methodsEach calibration method is detailed in a separate manual. Following is a briefdescription of the methods available.

Calibration Pendulum - standard methodCalibration Pendulum is the standard method for calibration of all ABB robots(except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the mostaccurate method for the standard type of calibration. It is the recommended methodin order to achieve proper performance.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 completetoolkit, including the Operating manual - Calibration Pendulum, which describesthe method and the different routines further.

Levelmeter calibration - alternative methodLevelmeter calibration is referred to as the alternative method for calibration ofABB robots because of the less accurate values obtained during calibration. Themethod uses the same principles as Calibration Pendulum, but does not have asgood of mechanical tolerances to the toolkit parts as the standard method withCalibration Pendulum.This method may, after calibration, require modifications in the robot program andis therefore not recommended.The calibration equipment (Levelmeter 2000) for levelmeter calibration is orderedas separate parts for each robot, and includes the Operating manual - LevelmeterCalibration, which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibrationTo achieve a good positioning in the Cartesian coordinate system, AbsoluteAccuracy calibration is used as a TCP calibration. The CalibWare tool guidesthrough 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 newabsolute accuracy calibration is required in order to establish full performance.For most cases after motor and transmission replacements that do not includetaking apart the robot structure, standard calibration is sufficient. Standardcalibration also supports wrist exchange.

ReferencesArticle numbers for the calibration tools are listed in the section Special tools onpage 278.The calibration equipment for Calibration Pendulum is delivered as a completetoolkit, including the Operating manual - Calibration Pendulum, which describesthe method and the different routines further.


5 Calibration5.2 Calibration methods

Continued

5.3 Calibration scale and correct axis position

IntroductionThis section specifies the calibration scale positions and/or correct axis positionfor all robot models.

Calibration scales, IRB 4400The illustration shows the calibration scale positions on IRB 4400. The calibrationmarks for axes 2, 3, 4 and 5 are marked using punch mark tools.

xx0300000209

Punch, axis 2, 3HAB 1521-1A

Punch, axis 3, 3HAB 1522-1B



5 Calibration5.3 Calibration scale and correct axis position

Punch, axis 4, 3HAB 1523-1 (there are two different versions of the marks, asshown in the figure)

C

Punch, axis 5, 3HAB 1524-1D


5 Calibration5.3 Calibration scale and correct axis position

Continued

5.4 Calibration movement directions for all axes

OverviewWhen calibrating, the axis must consistently be run towards the calibration positionin the same direction in order to avoid position errors caused by backlash in gearsand so on. Positive directions are shown in the graphic below.This is normally handled by the robot calibration software.

Calibration movement directions, 6 axesNote! The graphic shows an IRB 7600. The positive direction is the same for all6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in theopposite direction!

xx0200000089


5 Calibration5.4 Calibration movement directions for all axes

5.5 Updating revolution counters

IntroductionThis section describes how to do a rough calibration of each manipulator axis,which is updating the revolution counter value for each axis using the FlexPendant.

Step 1 - Manually running the manipulator to the calibration positionUse this procedure to manually run the manipulator to the calibration position.

NoteAction

Select axis-by-axis motion mode.1

See Calibration scale and correct axis po-sition on page 256.

Jog the manipulator to place the calibrationmarks within the tolerance zones.IRB 140, 1400, 2400, 4400, 6600ID/6650ID,6640ID: Axes 5 and 6 must be positionedtogether!

2

Step 2 - Storing the revolution countersettingwith theTPUonpage260 (BaseWare4.0).

When all axes are positioned, store the re-volution counter settings.

3

Step 2 - Storing the revolution countersetting with the FlexPendant on page 261.

Correct calibration position of axis 4 and 6When running the manipulator to calibration position, it is extremely important tomake sure that axes 4 and 6 of the following mentioned manipulators are positionedcorrectly. The axes can be calibrated at the wrong turn, resulting in an incorrectlycalibrated manipulator.Make sure the axes are positioned according to the correct calibration values, notonly according to the calibration marks. The correct values are found on a label,located either on the lower arm, underneath the flange plate on the base or on theframe.At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 atpower up before the revolution counters are updated.If one of the following mentioned axes are rotated one or more turns from itscalibration position before updating the revolution counter, the correct calibrationposition will be lost due to uneven gear ratio. This affects the following manipulators:

Axis 6Axis 4Manipulator variant

NoNoIRB 4400

If the calibration marks seem to be wrong (even if the motor calibration data iscorrect), try to rotate the axis one turn, update the revolution counter and checkthe calibration marks again (try both directions, if needed).



5 Calibration5.5 Updating revolution counters

Step 2 - Storing the revolution counter setting with the TPUUse this procedure to store the revolution counter setting with the TPU (BaseWare4.0).

NoteAction

Press the button Miscellaneous then ENTER to select the servicewindow.

xx0100000194

1

Select Calibration from the View menu.The Calibration window appears.If there is more than one unit connected to the manipulator, they willbe listed in the window.

xx0100000201

2

Select the desired unit and chooseRev Counter Update from theCalibmenu.The Revolution Counter Update window appears.

xx0100000202

3

Select the desired axis and press Incl to include it (it will be markedwith an x) or press All to select all axes.

4

Press OK when all axes that are to be updated are marked with an x.CANCEL returns to the Calibration window.

5

Press OK again to confirm and start the update.CANCEL returns to the Revolution Counter Update window.

6




Continued

NoteAction

Not required.At this point, it is recommended that the revolution counter values aresaved to a diskette.

7

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrectmanipulator positioning, which in turn may cause damage or injury!Check the calibration position very carefully after each update.

8

How to perform the check is detailed in sectionChecking the calibrationposition on page 263.

Step 2 - Storing the revolution counter setting with the FlexPendantUse this procedure to store the revolution counter setting with the FlexPendant(IRC5).

Action

On the ABB menu, tap Calibration.1All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.2A screen is displayed, tap Rev. Counters.

en0400000771

Tap Update Revolution Counters....A dialog box is displayed warning that updating the revolution counters may changeprogrammed manipulator positions:

• Tap Yes to update the revolution counters.• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

3




Continued

Action

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.

4

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 ticked revolution counters and removes the tick from thelist of axes.

5

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-tioning, which in turn may cause damage or injury!Check the calibration position very carefully after each update. See Checking thecalibration position on page 263.

6



Continued

5.6 Checking the calibration position

IntroductionCheck the calibration position before beginning any programming of the robotsystem. 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 on the TPU, S4CplusUse this procedure to create a program that runs all the robot axes to their zeroposition

NoteAction

Create the following program:MoveAbsJ [[0,0,0,0,0,0], [9E9,

9E9,9E9,9E9,9E9,9E9]]\NoEOffs, v1000, z50, Tool0

1

Run the program in manual mode.2

See Calibration scale and correctaxis positiononpage256, andUpdat-ing revolution counters on page259.

Check that the calibration marks for the axes aligncorrectly. If they do not, update the revolutioncounters.

3

Using a MoveAbsJ instructionUse this procedure to create a program that runs all the robot axes to their zeroposition.

NoteAction

On ABB menu tap Program editor.1

Create a new program.2

Use MoveAbsJ in the Motion&Proc menu.3

Create the following program:MoveAbsJ [[0,0,0,0,0,0],

[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs, v1000, z50, Tool0

4

Run the program in manual mode.5

See Calibration scale and correctaxis position on page256, andUpdat-ing revolution counters on page259.

Check that the calibration marks for the axes aligncorrectly. If they do not, update the revolutioncounters.

6

Using the jogging window on the TPU, S4CplusUse this procedure to jog the robot to zero position of all axes.

Illustration/NoteAction

xx0100000195

Open the Jogging window.1



5 Calibration5.6 Checking the calibration position

Illustration/NoteAction

xx0100000196

Select running axes-by-axes.2

Manually run the robot axes to a positionwhere the axis position value read on theTPU, is equal to zero.

3

See Calibration scale and correct axispositiononpage256, andUpdating revolu-tion counters on page 259.

Check that the calibration marks for the axesalign correctly. If they do not, update the re-volution counters.

4

Using the jogging windowUse this procedure to jog the robot to the zero position of all axes.

NoteAction

On the ABB menu, tap Jogging.1

Tap Motion mode to select group of axesto jog.

2

Tap to select the axis to jog, axis 1, 2, or3.

3

Manually run the robots axes to a positionwhere the axis position value read on theFlexPendant, is equal to zero.

4

SeeCalibration scale and correct axis pos-ition on page 256, and Updating revolutioncounters on page 259.

Check that the calibration marks for theaxes align correctly. If they do not, updatethe revolution counters!

5


5 Calibration5.6 Checking the calibration position

Continued

5.7 Additional calibration instruction, IRB 4400

InstructionBefore updating the revolution counters (coarse calibration) on IRB 4400, thestainless steel metal ring on axis 4 need to be removed.

Illustration

A

BC

xx0600003124

Upper armA

Stainless steel ringB

Hose clampC


5 Calibration5.7 Additional calibration instruction, IRB 4400

6 Decommissioning6.1 Environmental information

Hazardous materialThe table specifies some of the materials in the product and their respective usethroughout the product.Dispose components properly to prevent health or environmental hazards.

Example applicationMaterial

Serial measurement boardBatteries, NiCad or Lithium

Cables, motorsCopper

Base, lower arm, upper armCast iron/nodular iron

Gears, screws, base frame, and so on.Steel

Brakes, motorsNeodymium

Cables, connectors, drive belts, and so on.Plastic/rubber

GearboxesOil, grease

Covers, synchronization bracketsAluminium

Oil and greaseWhere possible, arrange for oil and grease to be recycled. Dispose of via anauthorized person/contractor in accordance with local regulations. Do not disposeof oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incinerationmust be carried out under controlled conditions in accordance with local regulations.Also note that:

• Spills can form a film on water surfaces causing damage to organisms.Oxygen transfer could also be impaired.

• Spillage can penetrate the soil causing ground water contamination.


6 Decommissioning6.1 Environmental information

7 Reference information7.1 Introduction

GeneralThis chapter includes general information, complementing the more specificinformation in the different procedures in the manual.


7 Reference information7.1 Introduction

7.2 Applicable safety standards

Standards, EN ISOThe manipulator system is designed in accordance with the requirements of:

DescriptionStandard

Safety of machinery - Basic concepts, general principles fordesign - Part 1: Basic terminology, methodology

EN ISO 12100 -1

Safety of machinery - Basic concepts, general principles fordesign - Part 2: Technical principles

EN ISO 12100 -2

Safety of machinery, safety related parts of control systems -Part 1: General principles for design

EN ISO 13849-1

Safety of machinery - Emergency stop - Principles for designEN ISO 13850

Robots for industrial environments - Safety requirements -Part1 Robot

EN ISO 10218-1 i

Manipulating industrial robots, coordinate systems, and motionnomenclatures

EN ISO 9787

Manipulating industrial robots, performance criteria, and relatedtest methods

EN ISO 9283

Classification of air cleanlinessEN ISO 14644-1 ii

Ergonomics of the thermal environment - Part 1EN ISO 13732-1

EMC, Generic emissionEN IEC 61000-6-4(option 129-1)

EMC, Generic immunityEN IEC 61000-6-2

Arc welding equipment - Part 1: Welding power sourcesEN IEC 60974-1 iii

Arc welding equipment - Part 10: EMC requirementsEN IEC 60974-10 iii

Safety of machinery - Electrical equipment of machines - Part1 General requirements

EN IEC 60204-1

Degrees of protection provided by enclosures (IP code)IEC 60529i There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times are

documented.ii Only robots with protection Clean Room.iii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

DescriptionStandard

Safety of machinery - Ergonomic design principles - Part 1:Terminology and general principles

EN 614-1

Safety of machinery - Two-hand control devices - Functionalaspects - Principles for design

EN 574

Safety of machinery - General requirements for the design andconstruction of fixed and movable guards

EN 953

Other standards

DescriptionStandard

Safety requirements for industrial robots and robot systemsANSI/RIA R15.06



7 Reference information7.2 Applicable safety standards

DescriptionStandard

Safety standard for robots and robotic equipmentANSI/UL 1740(option 429-1)

Industrial robots and robot Systems - General safety require-ments

CAN/CSA Z 434-03(option 429-1)


7 Reference information7.2 Applicable safety standards

Continued

7.3 Unit conversion

Converter tableUse the following table to convert units used in this manual.

UnitsQuantity

39.37 in3.28 ft.1 mLength

2.21 lb.1 kgWeight

0.035 ounces1 gWeight

14.5 psi100 kPa1 barPressure

0.225 lbf1 NForce

0.738 lbf-ft1 NmMoment

0.264 US gal1 LVolume


7 Reference information7.3 Unit conversion

7.4 Screw joints

GeneralThis section describes how to tighten the various types of screw joints on the IRB4400.The instructions and torque values are valid for screw joints comprised of metallicmaterials and do not apply to soft or brittle materials.

UNBRAKO screwsUNBRAKO is a special type of screw recommended by ABB for certain screw joints.It features special surface treatment (Gleitmo as described below) and is extremelyresistant to fatigue.Whenever used, this is specified in the instructions, and in such cases, no othertype of replacement screw is allowed. Using other types of screws will void anywarranty and may potentially cause serious damage or injury.

Gleitmo treated screwsGleitmo is a special surface treatment to reduce the friction when tightening thescrew joint. Screws treated with Gleitmo may be reused 3-4 times before the coatingdisappears. After this the screw must be discarded and replaced with a new one.When handling screws treated with Gleitmo, protective gloves of nitrile rubbertype should be used.

Screws lubricated in other waysScrews lubricated with Molycote 1000 should only be used when specified in therepair, 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 wrenchif this is done by trained and qualified personnel.

Art. no.Lubricant

11712016-618Molycote 1000 (molybdenum disulphide grease)

Tightening torqueBefore tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to beapplied. The standard torques are specified in the following tables. Anyspecial torques are specified in the repair, maintenance or installationprocedure descriptions.Any special torque specified overrides the standardtorque!

• Use the correct tightening torque for each type of screw joint.• Only use correctly calibrated torque keys.



7 Reference information7.4 Screw joints

• 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 screwsThe following table specifies the recommended standard tightening torque foroil-lubricated screws with slotted or cross-recess head screws.

Tightening torque (Nm)Class 4.8, oil-lubricated

Dimension

0.25M2.5

0.5M3

1.2M4

2.5M5

5.0M6

Oil-lubricated screws with allen head screwsThe following table specifies the recommended standard tightening torque foroil-lubricated screws with allen head screws.

Tightening torque (Nm)Class 12.9, oil-lubric-ated

Tightening torque (Nm)Class 10.9, oil-lubric-ated

Tightening torque (Nm)Class 8.8, oil-lubricated

Dimension

--6M5

--10M6

403424M8

806747M10

14011582M12

340290200M16

670560400M20

1150960680M24

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screwsThe following table specifies the recommended standard tightening torque forscrews lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen headscrews.

Tightening torque (Nm)Class 12.9, lubricated i


Dimension

3528M8

7055M10

12096M12

280235M16

550460M20




Continued



Dimension

950790M24i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectorsThe following table specifies the recommended standard tightening torque forwater and air connectors when one or both connectors are made of brass.

Tightening torque Nm -Max.

Tightening torque Nm -Min.

Tightening torque Nm -Nominal

Dimension

158121/8

2010151/4

2515203/8

5030401/2

9055703/4



Continued

7.5 Weight specifications

DefinitionIn installation, repair, and maintenance procedures, weights of the componentshandled are sometimes specified. All components exceeding 22 kg (50 lbs) arehighlighted in this way.To avoid injury, ABB recommends the use of a lifting accessory when handlingcomponents with a weight exceeding 22 kg. A wide range of lifting accessoriesand devices are available for each manipulator model.

ExampleFollowing is an example of a weight specification in a procedure:

NoteAction

CAUTION

The robot weighs 1300 kg.All lifting accessories used must be sized accord-ingly!


7 Reference information7.5 Weight specifications

7.6 Standard tools

GeneralAll service (repairs, maintenance, and installation) procedures contains lists oftools required to perform the specified activity.All special tools required are listed directly in the procedures while all the toolsthat are considered standard are gathered in the standard toolkit and defined inthe following table.This way, the tools required are the sum of the standard toolkit and any tools listedin the instruction.

Contents, standard toolkit

ToolQty

Allen key 5-17 mm1

Socket with ratchet1

Box spanner set1

Screwdriver1

Torx socket no:20, 25, 301

Extension bar 100 mm1

Puller bar2

KM nut (KM10, KM17)1

Lifting hoist1

Cutting pliers1

Torque wrench 10-470 Nm1


7 Reference information7.6 Standard tools

7.7 Special tools

GeneralAll service instructions contain lists of tools required to perform the specifiedactivity. The required tools are a sum of standard tools, defined in the sectionStandard tools on page 277, and of special tools, listed directly in the instructionsand also gathered in this section.

Calibration equipment, Levelmeter (alternative method)The following table specifies the calibration equipment required when calibratingthe robot with the alternative method, Levelmeter Calibration.

NoteArt. no.Description

68080011-LPAngle bracket

3HAC13908-9Calibration bracket

3HAC13908-4Calibration tool ax1

Includes one sensor.6369901-347Levelmeter 2000 kit

3HAC13908-5Measuring pin

68080011-GMSensor fixture

3HAC0392-1Sensor plate

3HAC13908-1Sync. adapter

3HAC68080011-GUTurn disk fixture

Calibration equipment, Calibration PendulumThe following table specifies the calibration equipment needed when calibratingthe robot with the Calibration Pendulum method.

NoteArt. no.Description

Complete kit that also includes operatingmanual.

3HAC15716-1Calibration Pendulum toolkit


7 Reference information7.7 Special tools

7.8 Lifting accessories and lifting instructions

GeneralMany 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 bestored for later reference.


7 Reference information7.8 Lifting accessories and lifting instructions

8 Part list8.1 Introduction

OverviewThis section specifies all the replacement articles of the robot. The parts are shownin Exploded views on page 291.Specific spare parts are listed separately in a Spare part list.


8 Part list8.1 Introduction

8.2 Manipulator

Part list, manipulatorSee the Foldout 1, 2, 3:1, 3:2, 4 and 5 for location of parts.

NoteArt.noNameQtyItem

3HAC5947-1Foot11

3HAC5948-1Gear box axes 1-312

M16x80 8.8, Gleitmo 6103HAB7700-88Screw263

3HAA1001-186Washer144

3HAC 5952-1Motor unit axis 1 (Elmo)15

3HAC021724-001Motor unit axis 1 (Yaskawa)15

3HAC5954-1Motor unit axes 2 and 3 (Elmo)26

3HAC021725-001Motor unit axes 2 and 3(Yaskawa)

26

149x42152 0431-11O-ring37

10.5x23x2.52154 2033-10Spring washer128

M10x70 12.9, Gleitmo3HAB3409-59Screw49

M10x30 12.9, Gleitmo610

3HAB3409-51Screw810

3HAC5955-1Lower arm111

3HAB3640-1Spring washer212

M16x55 12.9, Gleitmo610

3HAB3409-85Screw1013

3HAB9237-1Cushion axis 2414

3HAB3648-1Cushion axis 3215

M6x16 89ADA629-56Screw2016

3HAB8466-1Parallel arm 60 kg118

3HAB3732-11V-ring119

618303HAB3710-14Groove ball bearing120

3HAB3749-1Sealing ring121

3HAC7409-1Washer222

3HAB3701-25Sealing223

3HAC4160-1Washer224

3HAC15083-1Balancing unit125

3HAC3970-1Shaft226

3HAB3757-17Needle roller bearing127

3HAC4168-1Securing plate128

3HAB3647-1Stop pin129

3HAB3741-1Cushion130

M8x30 8.89ADA183-38Screw131



8 Part list8.2 Manipulator


8.4x16x1.69ADA312-7Plain washer132

M10x129ADA205-73Stop screw133

3HAB3755-1Sync. market axis 3134

3HAB3704-1Washer235

M8x16 8.82121 2851-449Screw436

Where to find type of oiland total amount is de-tailed in Type andamount of oil in gear-boxes on page 115.

-Lubricating oil-37

200 g3HAB3537-1Grease38

1 ml, Loctite 2431269 0014-429Locking liquid39

3HAB3701-26Sealing ring40


100 ml3HAC2331-1Grease42

6.3 x 2.43HAC4156-1Bearing sleeve443

3HAC4334-2Cylindrical roller bearing144

M10x16 8.89ADA183-48Screw146

10.5x20x29ADA312-8Plain washer147

3HAC4162-1Holder148

3HAC3977-1Bushing249

3HAC3297-1Sealing250

3HAC1621-1Parallel bar151

3HAA2167-11Spher. roller bearing252

3HAC3990-11Sealing without dustlip253

3HAC17542-1Upper arm without wrist andmotors

154

3HAC7877-1Sealing with dustlip255

3HAA2103-13Tapper roller bearing256

80x103HAA2166-11VK-cover257

M50x1.521262851-110Lock nut258

3HAC4744-1Shaft end259

3HAB3754-1Sync. market axis 2160

6.4x22x1.53HAA2356-13Washer461

3HAC3943-1Step protector163

3HAC0127-1Air ventilation plug364


3HAB3772-23O-ring266






Continued


3HAC5958-1Cable unit axis 1-31100

3HAC8304-1Cable unit axis 4-61101

3HAC3692-1Bottom plate1102

3HAC3688-1Gasket1103

3HAC8306-1Cover1104

3HAC3547-1Gasket1105

3HAC3388-1Cable bushing1106

3HAC4116-1Bracket1107

3HAB3299-1Holder for cable guide2108

3HAB3756-1Cable guide1109

3HAB3662-1Spring1110

3HAB3699-1Cable guide upper arm1111

3HAC2327-1Cover3112

3HAC3585-1Cover punchb. 44001113

3HAB3666-1Cover1114

M5x16 8.821212416-329Screw23116

M5 fzb9ADA290-1Nut with flange20118

4.8x20821662055-3Straps, outdoor30119

M5x12 8.821212172-228Bolt with flange22120

3HAA0001-ADXPush button unit1121

M5x1521252052-198Distance bolt4122

3HAC2744-1Pushbutton guard1123

M4x1221212477-291Screw8124

5217687-22Housing 64-p1125

3HAB8431-1Designition sign1126

M5x109ADA629-43Screw36127

IRB 4450S3HAC024590-001Bracket1128(Only for protection type Stand-ard.)

M20x90, UNBRAKO 12.93HAC4867-11Screw2130

3HAC7561-3Dust cap2132

3HAC7561-4Dust cap1133

M8x12 8.89ADA183-34Screw6135

M5x12 89ADA629-44Screw34137

2.5x101 mm21662054-1Cable strap, indoor15138

3HAB3333-20Coupling1139

1 ml, Loctite 54212690014-412Locking liquid140

D=11.4 - 1325222101-8Protective hood3141




Continued


9ABA142-62Spring pin2144

3HAB3675-1Gasket3147


1 ml, Loctite 57412340011-116Flange sealing150


M5x20 8.89ADA618-46Screw9153


3HAB6411-1Housing 40-p1155

196.5x254x15/10 BAB 6SL NLR

2522290-32SIM-ring1A

Polyamide 6.6, black,7.6x368

21662055-6Cable starps, outdoor4158

Steel 12.9 M10x40,Gleitmo 610

3HAB3409-50Hex socket head cap screw4161

Instructions included3HAC037052-001Touch up paint Foundry Prime,orange

Instructions included3HAC035355-001Touch up paint Foundry Prime2, grey



Continued

8.3 Upper arm part, axes 4-6

Part list, upper arm partSee the Foldout 6:1, 6:2 and 6:3 for location of parts.


Protection type Foundry, but alsoused for protection type Standard.

3HAC17542-1Upper arm withoutwrist and motors.

1

M8x40 8.8-A2F9ADA183-40Hex socket headcap screw

121

8.4x16x1.6 A2F9ADA312-7Plain washer102

M10x60 12.9. Gleitmo 6103HAB3409-57Hex socket headcap screw

34

10.5x23x2.5 fzm21542033-10Spring washer35

3HAB3759-1Stop axis 4113

3HAB3760-1Damper114

M8x16 8.89ADA183-35Screw415

M10x30 12.9. Gleitmo 6103HAB3409-51Screw825

10.5x20x29ADA312-8Plain washer826

199.3x5.721522012-541O-ring127

3HAB3613-1Gear, axis 6129

1 ml, Loctite 57412340011-116Flange sealing131

R1/4”2522122-1Magnetic plug433

13.7x20.621522031-6Sealing washer434

Where to find type of oil and totalamount is detailed in Type andamount of oil in gearboxes onpage 115.

-Lubricating oil-35

74.5x321522012-426O-ring348

3HAC10603-1Motor unit axis 4with pinion (Elmo)

149


149

3HAC021726-001Motor unit axis 4with pinion(Yaskawa)

149


149


150


150

M6x25 12.9, Gleitmo 6103HAB3409-26Screw2451



8 Part list8.3 Upper arm part, axes 4-6


6.4x14x1.521542033-7Conical springwasher

1252

Option 04y. See figure below!3HAC8820-1Customer cable ex-tension, axis 4

152

Cover axis 4156

M8x30 12.9 Gleitmo 610, L/103HAB3409-38Hex socket headcap screw

657

Signal cabling, upper arm

xx0300000409


8 Part list8.3 Upper arm part, axes 4-6

Continued

8.4 Serial measurement unit

Part list, serial measurement unitSee the Foldout 7 for location of parts.

NoteArt.no.NameItem

RMU3HAC044075-001Battery pack (3-pole battey con-tact)

3LithiumCan only be used with SMBunit 3HAC046277-001 con-taining SMB board3HAC044168-001.

Lithium3HAC16831-1Battery pack (2-pole battery con-tact)

3Can only be used with SMBunit 3HAC17396-1 contain-ing SMB board3HAC031851-001.

NiCd 7.2 V 4 Ah4944026-4Battery pack3Can not be used with serialmeasurement units3HAC046277-001 and3HAC17396-1.

L=368 mm21662055-6Straps, outdoor4

Contains serial measure-ment board 3HAC031851-001 and battery pack3HAC16831-1.

3HAC17396-1Serial measurement unit5

Contains serial measure-ment board 3HAC044168-001 and battery pack3HAC044075-001.

3HAC046277-001Serial measurement unit5

DSQC 633A3HAC031851-001Serial measurement board5

RMU 1013HAC044168-001Serial measurement board5

3HAC7819-1Serial cable7

L=208 mm21662055-3Straps, outdoor8

38x1929401413-1Label9


8 Part list8.4 Serial measurement unit

8.5 Position switch, axis 1

Part list, position switchSee the Foldout 8 for location of parts.

NoteArt.no.NameQtyItem

Option 25-2 Standard,complete set

3HAC12042-1Pos. switch ax 1, 1 sw1

Option 25-2 Foundry,complete set










7 m3HAC7997-1Pos. switch cable1




ax1 pos.sw. (one) option3HAC8039-1Position switch 111

ax1 pos.sw. (two) option3HAC8040-1Position switch 1-211

ax1 pos.sw. (three) option3HAC8041-1Position switch 1-311

ax1 pos.sw. (one, two,three)

3HAC6474-1Segment Foundry12

ax1 pos.sw. (one)3HAC4476-1Cam, blank33

ax1 pos.sw. (two)3HAC4476-1Cam, blank53

ax1 pos.sw. (three)3HAC4476-1Cam, blank73

ax1 pos.sw. (one, two,three)

3HAC6558-1Bracket Foundry14

2 1914-04 M6x55 protec-tion (foundry)

21252052-216Distance bolt45

Steel 8-A2F, M4x20, pro-tection (foundry)

9ADA629-56Torx pan head roll. screw35

Steel 8.8-A2F. M4x20ax1possw(one)

9ADA183-6Hex socket head cap screw26

Steel 8.8-A2F. M4x20ax1possw(two)


Steel 8.8-A2F. M4x20ax1possw(three)


ax1possw(one)3HAB7478-1Shims-sheet47

ax1possw(two)3HAB7478-1Shims-sheet87

ax1possw(three)3HAB7478-1Shims-sheet127



8 Part list8.5 Position switch, axis 1

NoteArt.no.NameQtyItem

Steel 8.8-A2F, M6x10ax1possw(one)


Steel 8.8-A2F,M6x10ax1possw(two)


Steel 8.8-A2F,M6x10ax1possw(three)


Limit position switch3HAC8057-1Bracket position switch110

Steel 8-A2F, M5 ax1pos-sw(one)

9ADA267-5Hexagon nut111

Steel 8-A2F, M5ax1pos-sw(two)


Steel 8-A2F, M5ax1pos-sw(three)


Polyamide 6.6 black4.8x208, ax1possw (one,two, three)

21662055-3Cable straps, outdoors112

B-619, 38x19 mm ax1pos-sw (one, two, three) Text:R1.LS1. Text height 3 mm

29401413-1Label115

Steel 8.8 Fe/Zn 5c, M8x16,ax1possw (one, two,three)

21212852-449Hex socket counters, head617

ax1possw(one, two, three)3HAB5617-1Earth symbol119

3HAC7821-1Assembly instruction120

Steel-A2F 5.3x10x1ax1possw(one)

9ADA312-5Plain washer121

Steel-A2F 5.3x10x1ax1possw(two)


Steel-A2F 5.3x10x1ax1possw(three)


ax1possw(three)3HAB8389-1Plain washer622

Steel 8.8-A2F, M6x30,ax1possw (one, two,three)

9ADA618-59 *Torx pan head roll. screw223

Protection Foundry3HAC6475-1Box foundry switch124

Steel 8.8-A2F, M6x12 pro-tection Foundry

9ADA618-55Torx pan head screw425

* Excisting screws must be exchanged to this longer screws


8 Part list8.5 Position switch, axis 1

Continued

9 Exploded views9.1 Introduction

DefinitionsThis chapter contains detailed views of the components on the manipulator.The numbered details are specified with item numbers in the Part list on page281.The exploded views are divided into:

• Exploded view 1-5: Manipulator (part list: Manipulator on page 282)• Exploded view 6.1- 6.3: Upper arm part, axes 4-6 (part list: Upper arm part,

axes 4-6 on page 286)• Exploded view 7: Serial measurement unit (part list: Serial measurement unit

on page 288)• Exploded view 8: Position switch, axis 1 (part list: Position switch, axis 1 on

page 289)


9 Exploded views9.1 Introduction

9.2 Exploded views

Exploded view 1F 1 tuodlo

xx1100000361



9 Exploded views9.2 Exploded views


xx1100000362




Continued

Exploded view 3:1F 3 tuodlo 1:

xx1100000365




Continued


xx1100000366




Continued


xx1100000367




Continued

Exploded view 6:1F 1:6 tuodlo

xx1100000368




Continued

Exploded view 6:2F 2:6 tuodlo

xx1100000369




Continued

Exploded view 7

9

x/1-5633 bah3

reS mei ä tehnet

4 3

.1R BMS

BMS.2R

G.1R

8 5 7

F 7 tuodlo

xx1100000371




Continued


xx1100000372



Continued

10 Circuit diagram10.1 About circuit diagrams

OverviewThe circuit diagrams are not included in this manual, but delivered as separatedocuments on the documentation DVD. See the article numbers in the tables below.

Controllers

Article numbers for circuit diagramsProduct

3HAC024480-005Circuit diagram - IRC5 (drive system 09)

3HAC031403-003Circuit diagram - IRC 5 Compact

3HAC026871-006Circuit diagram - IRC5 Panel Mounted Con-troller

3HAC024120-004Circuit diagram - Euromap

Robots


3HAC031408-003Circuit diagram - IRB 120

3HAC6816-3Circuit diagram - IRB 140 type C







3HAC021351-003Circuit diagram - IRB 1600 type A




3HAC9821-1Circuit diagram - IRB 4400/4450S


3HAC8935-1Circuit diagram - IRB 6400RF

3HAC13347-1Circuit diagram - IRB 6600 type A3HAC025744-001

3HAC13347-1Circuit diagram - IRB 6600 type B3HAC025744-001


3HAC025090-001Circuit diagram - IRB 6620 / IRB 6620LX






3HAC13347-1Circuit diagram - IRB 6650S3HAC025744-001

3HAC025744-001Circuit diagram - IRB 66603HAC029940-001

3HAC13347-1Circuit diagram - IRB 76003HAC025744-001



Continued

IndexAAbsolute Accuracy, calibration, 255air quality, 57aluminum

disposal, 267

Bbatteries

disposal, 267handling, 51

batterySMB, 108

battery packreplacing, interval, 102–103

brakestesting function, 32

Ccalibrating

roughly, 259calibration

Absolute Accuracy type, 254alternative method, 255Levelmeter calibration, 255rough, 259standard type, 254when to calibrate, 253

calibration, Absolute Accuracy, 255calibration manuals, 255calibration marks, 256calibration position, 259

checking, 263jogging to, 264jogging to, TPU, 263scales, 256

calibration scales, 256CalibWare, 254carbon dioxide extinguisher, 30cast iron

disposal, 267cleaners

approved, 112requirements, 111

cleaningrobot, 110

connectionexternal safety devices, 19

copperdisposal, 267

Ddanger levels, 38detergents

approved, 112requirements, 111

direction of axes, 258

Eemergency stop

definition, 36devices, 37

enabling device, 34environmental information, 267ESD

damage elimination, 49sensitive equipment, 49wrist strap connection point, 49

Ffence dimensions, 29fire extinguishing, 30FlexPendant

jogging to calibration position, 264MoveAbsJ instruction, 263updating revolution counters, 261

foundationrequirements, 61

Ggrease

disposal, 267

Hhazardous material, 267hold-to-run, 34

Iinstallation

mechanical stop axis 2, 81position switch axis 3, 84

Llabels

manipulator, 40Levelmeter calibration, 255lifting accessory, 276Lithium

disposal, 267

Mmain power

switching off, 47main switch

controller cabinet, 47control module, 48drive module, 48

manipulatorsymbols, 40

mechanical stopaxis 2, 81

MoveAbsJ instruction, 263TPU, 263

Nnegative directions, axes, 258neodymium

disposal, 267NiCad

disposal, 267nodular iron

disposal, 267

Ooil

disposal, 267oil change

safety risks, 52


Index

Ppaint surface damages, 107plastic

disposal, 267position switch

axis 3, 84positive directions, axes, 258pressurized components

air quality, 57Foundry Prime, 56

protection classes, 61protection standards, 270

Rrepair

painted surface, 107requirements on foundation, 61responsibility and validity, 19restricting

working range axis 2, 81working range axis 3, 84

revolution countersstoring on FlexPendant, 261storing on TPU, 260updating, 259

risk of tipping, 88robot

cleaning, 110protection class, 61symbols, 40

rubberdisposal, 267

Ssafety

brake testing, 32emergency stop, 36ESD, 49fence dimensions, 29fire extinguishing, 30FlexPendant, 34introduction, 17manipulator system, 19moving manipulators, 45reduced speed function, 33release manipulator arm, 31service, 19signals, 38signals in manual, 38symbols, 38symbols on manipulator, 40test run, 46working range, 35wrist strap, 49

safety equipmentmechanical stop axis 2, 81position switch axis 3, 84

safety riskelectric parts, 27hot parts, 23

hydraulic system, 25installation, 20oil change, 52operational disturbance, 26pneumatic system, 25service work, 20tools, 24voltage, 27work pieces, 24

safety signalsin manual, 38

safety standards, 270scales on robot, 256sensitive points

Foundry Prime, 58signals

safety, 38SMB battery

replacing, 108special tools, 278stability, 88standards

ANSI, 270CAN, 270EN, 270EN IEC, 270EN ISO, 270protection, 270safety, 270

steeldisposal, 267

symbolssafety, 38

sync marks, 256

Ttesting

brakes, 32tools

calibration equipment, Levelmeter, 278Calibration Pendulum equipment, 278for service, 278

TPUjogging to calibration position, 263MoveAbsJ instruction, 263updating revolution counters, 260

Uupdating revolution counters, 259

Vvalidity and responsibility, 19

Wweight

robot, 63, 70, 155, 157, 160–161, 165–166, 183–184, 191–192, 196, 199, 238, 240, 276

working rangerestricting axis 2, 81restricting axis 3, 84


Index

Contact us

ABB ABDiscrete Automation and MotionRoboticsS-721 68 VÄSTERÅS, SwedenTelephone +46 (0) 21 344 400

ABB AS, RoboticsDiscrete Automation and MotionBox 265N-4349 BRYNE, NorwayTelephone: +47 51489000

ABB Engineering (Shanghai) Ltd.5 Lane 369, ChuangYe RoadKangQiao Town, PuDong DistrictSHANGHAI 201319, ChinaTelephone: +86 21 6105 6666

ABB Inc.Discrete Automation and MotionRobotics1250 Brown RoadAuburn Hills, MI 48326USATelephone: +1 248 391 9000

www.abb.com/robotics

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