abb product manual irb4600

ABB Robotics

Product manualIRB 4600

Trace back information:Workspace R13-2 version a3Checked in 2013-10-15Skribenta version 4.0.378

Product manual

IRB 4600 - 60/2.05IRB 4600 - 45/2.05IRB 4600 - 40/2.55IRB 4600 - 20/2.50

M2004

Document ID: 3HAC033453-001

Revision: H

Copyright 2009-2013 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.


ABB ABRobotics ProductsSe-721 68 Vsters

Sweden

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

16Product documentation, IRC5 ..........................................................................................................18How to read the product manual ......................................................................................................

191 Safety

191.1 Introduction to safety information .........................................................................201.2 General safety information ..................................................................................201.2.1 Introduction to general safety information ....................................................211.2.2 Safety in the manipulator system ...............................................................221.2.3 Safety risks ............................................................................................221.2.3.1 Safety risks during installation and service work on manipulators .........251.2.3.2 CAUTION - Hot parts may cause burns! ...........................................261.2.3.3 Safety risks related to tools/work pieces ..........................................271.2.3.4 Safety risks related to pneumatic/hydraulic systems ..........................281.2.3.5 Safety risks with pressure relief valve ..............................................291.2.3.6 Safety risks during operational disturbances .....................................301.2.3.7 Risks associated with live electric parts ...........................................321.2.4 Safety actions .........................................................................................321.2.4.1 Safety fence dimensions ...............................................................331.2.4.2 Fire extinguishing ........................................................................341.2.4.3 Emergency release of the manipulators arm ....................................351.2.4.4 Brake testing ..............................................................................361.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................371.2.4.6 Safe use of the FlexPendant ..........................................................381.2.4.7 Work inside the manipulator's working range ...................................391.2.4.8 Signal lamp (optional) ...................................................................401.2.5 Safety stops ...........................................................................................401.2.5.1 What is an emergency stop? ..........................................................421.3 Safety related instructions ..................................................................................421.3.1 Safety signals in the manual ......................................................................441.3.2 Safety symbols on manipulator labels .........................................................491.3.3 DANGER - Moving manipulators are potentially lethal! ...................................501.3.4 DANGER - First test run may cause injury or damage! ...................................511.3.5 WARNING - The brake release buttons may be jammed after service work ........521.3.6 DANGER - Make sure that the main power has been switched off! ....................531.3.7 WARNING - The unit is sensitive to ESD! .....................................................541.3.8 WARNING - Safety risks during handling of batteries .....................................551.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......

572 Installation and commissioning

572.1 Introduction ......................................................................................................582.2 Unpacking .......................................................................................................582.2.1 Pre-installation procedure .........................................................................612.2.2 Working range and type of motion ..............................................................652.2.3 Risk of tipping/stability .............................................................................662.3 On-site installation ............................................................................................662.3.1 Lifting robot with roundslings ....................................................................692.3.2 Lifting and turning a suspended mounted robot ............................................702.3.3 Manually releasing the brakes ...................................................................732.3.4 Orienting and securing the robot ................................................................762.3.5 Setting the system parameters for a suspended robot ....................................782.3.6 Fitting equipment on robot ........................................................................842.3.7 Loads ....................................................................................................852.3.8 Installation of signal lamp (option) ..............................................................862.4 Restricting the working range ..............................................................................862.4.1 Introduction ............................................................................................

3HAC033453-001 Revision: H 5 Copyright 2009-2013 ABB. All rights reserved.

Table of contents

872.4.2 Mechanically restricting the working range of axis 1 ......................................902.5 Installing options ...............................................................................................902.5.1 Installation of cooling fan for motors (option) ................................................972.5.2 Installation of Foundry Plus Cable guard (option no. 908-1) .............................982.5.3 Installing an expansion container ...............................................................

1002.6 Robot in hot environments ..................................................................................1002.6.1 Start of robot in hot environments ..............................................................1012.7 Robot in cold environments .................................................................................1012.7.1 Start of robot in cold environments .............................................................1022.8 Electrical connections ........................................................................................1022.8.1 Robot cabling and connection points ..........................................................1042.8.2 Customer connection on robot ...................................................................1062.8.3 Customer connections on upper arm ..........................................................

1093 Maintenance

1093.1 Introduction ......................................................................................................1103.2 Maintenance schedule .......................................................................................1103.2.1 Specification of maintenance intervals ........................................................1113.2.2 Maintenance schedule .............................................................................1133.2.3 Expected component life .........................................................................1143.3 Inspection activities ...........................................................................................1143.3.1 Inspecting oil level, axis 1 gearbox .............................................................1213.3.2 Inspecting the oil level, axis 2 gearbox ........................................................1233.3.3 Inspecting the oil level, axis 3 gearbox ........................................................1263.3.4 Inspecting the oil level, axis 4 gearbox ........................................................1283.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................1323.3.6 Inspecting the cable harness .....................................................................1343.3.7 Inspecting information labels .....................................................................1373.3.8 Inspecting the mechanical stop pin, axis 1 ...................................................1403.3.9 Inspecting additional mechanical stops .......................................................1423.3.10 Inspecting dampers .................................................................................1443.3.11 Inspecting the pressure relief valve ............................................................1463.3.12 Inspecting Signal lamp (option) ..................................................................1483.4 Replacement activities .......................................................................................1483.4.1 Type of lubrication in gearboxes ................................................................1503.4.2 Changing the oil, axis-1 gearbox on floor mounted robots ...............................1563.4.3 Changing the oil, axis-1 gearbox on suspended robots ...................................1623.4.4 Changing the oil, axis-2 gearbox ................................................................1663.4.5 Changing the oil, axis-3 gearbox ................................................................1723.4.6 Changing the oil, axis-4 gearbox ................................................................1763.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................1823.4.8 Replacing SMB battery .............................................................................1873.5 Cleaning activities .............................................................................................1873.5.1 Cleaning, robot ......................................................................................

1894 Repair

1894.1 Introduction ......................................................................................................1904.2 General procedures ...........................................................................................1904.2.1 Performing a leak-down test ......................................................................1914.2.2 Mounting instructions for bearings .............................................................1934.2.3 Mounting instructions for seals ..................................................................1954.3 Complete robot .................................................................................................1954.3.1 Removing the complete cable harness ........................................................2074.3.2 Refitting the complete cable harness ..........................................................2234.3.3 Replacing SMB unit .................................................................................2284.3.4 Replacing the brake release unit ................................................................2324.3.5 Replacing the base ..................................................................................2424.4 Upper arm .......................................................................................................2424.4.1 Replacing the complete upper arm .............................................................

6 3HAC033453-001 Revision: H Copyright 2009-2013 ABB. All rights reserved.

Table of contents

2514.4.2 Replacing complete tubular shaft unit .........................................................2574.4.3 Replacing wrist unit .................................................................................2624.4.4 Measuring the play, axis 5 ........................................................................2654.4.5 Measuring the play, axis 6 .........................................................................2684.5 Lower arm .......................................................................................................2684.5.1 Replacing the lower arm ...........................................................................2754.6 Frame and base ................................................................................................2754.6.1 Replacing stop pin axis 1 ..........................................................................2784.7 Motors ............................................................................................................2784.7.1 Removing motors ....................................................................................2864.7.2 Refitting motors ......................................................................................2964.7.3 Adjusting the play of axis 4, 5 and 6 motors .................................................2974.8 Gearboxes .......................................................................................................2974.8.1 Replacing gearbox axis 1 ..........................................................................3034.8.2 Replacing gearbox axis 2 ..........................................................................3114.8.3 Replacing gearbox axis 3 ..........................................................................

3195 Calibration

3195.1 Introduction .....................................................................................................3205.2 Calibration methods ...........................................................................................3225.3 Calibration scale and correct axis position .............................................................3255.4 Calibration movement directions for all axes ..........................................................3265.5 Updating revolution counters ...............................................................................3285.6 Checking the calibration position ..........................................................................

3296 Decommissioning

3296.1 Introduction ......................................................................................................3306.2 Environmental information ..................................................................................

3317 Robot description

3317.1 Type C of IRB 4600 ............................................................................................

3338 Reference information

3338.1 Introduction ......................................................................................................3348.2 Applicable safety standards ................................................................................3368.3 Unit conversion .................................................................................................3378.4 Screw joints ....................................................................................................3408.5 Weight specifications .........................................................................................3418.6 Standard tools ..................................................................................................3428.7 Special tools ....................................................................................................3448.8 Lifting accessories and lifting instructions ..............................................................

3459 Spare part list

3459.1 Rebuilding parts ................................................................................................3479.2 Base cover assembly .........................................................................................3489.3 Base and frame unit ...........................................................................................3509.4 Lower arm and frame .........................................................................................3529.5 Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 ............................................3589.6 Wrist unit (60 kg/45 kg/20 kg) ..............................................................................3619.7 Electrical connections ........................................................................................3639.8 Gearboxes .......................................................................................................3659.9 Motors ............................................................................................................3679.10 Labels .............................................................................................................3689.11 Options ...........................................................................................................

36910 Circuit diagram

36910.1 About circuit diagrams .......................................................................................


Table of contents

371Index


Table of contents

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 robot described in this manual has the protection type Standard and FoundryPlus.

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 and calibration.

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 information that must be read through before performingany installation or service work on the robot. Contains generalsafety aspects as well as more specific information on how toavoid personal injuries and damage to the product.

Safety

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

Step-by-step procedures that describe how to perform mainten-ance of the robot. Based on a maintenance schedule that maybe used to plan periodical maintenance.

Maintenance

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

Repair

Procedures that do not require specific calibration equipment.General information about calibration.

Calibration information

Environmental information about the robot and its components.Decommissioning

Continues on next page3HAC033453-001 Revision: H 9


Overview of this manual

ContentsChapter

Useful information when performing installation, maintenanceor repair work. Includes lists of necessary tools, additional doc-uments, safety standards etc.

Reference information

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

Spare part / part list

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

Exploded views

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

References

Document IdReference

3HAC040585-001Product manual - IRB 4600 Foundry Prime

3HAC032885-001Product specification - IRB 4600

3HAC029038-003Circuit diagram - IRB 4600

3HAC021313-001Product manual - IRC5IRC5 with main computer DSQC 639.

3HAC047136-001Product manual - IRC5IRC5 with main computer DSQC1000.

3HAC027098-001Operating manual - Emergency safety information

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC020738-001Operating manual - Trouble shooting IRC5

3HAC16578-1Operating manual - Calibration Pendulum

3HAC025709-001Operating manual - Service Information System

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC17076-1Technical reference manual - System parameters

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

3HAC027709-001Application manual - Electronic Position Switches

3HAC030421-001Application manual - CalibWare Field 5.0

Revisions

DescriptionRevision

First edition-

Continues on next page10 3HAC033453-001 Revision: H



Continued

DescriptionRevision

The following updates have been made in this revision: NewWARNING! added in Safety chapter sectionWork inside themanip-

ulator's working range on page 38. New WARNING! added in Safety chapter section WARNING - Safety

risks during work with gearbox lubricants (oil or grease) on page 55. Information about the quality and used threadlength for attachment

screws on mounting flange, added in Installation chapter section Fittingequipment on wrist and mounting flange on page 82.

The text in the introduction to chapters Installation, Maintenance andRepair has been updated concerning the robot being connected to earthwhen power connected.

Levelmeter calibration added in sectionsCalibrationmethods on page321andCalibration equipment, Levelmeter (alternativemethod) on page342.

Section Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 onpage 352 in Spare parts updated with Type A spare parts.

Section Lifting and turning a suspendedmounted robot on page69 addedin Installation chapter.

Section Installation of Foundry Plus Cable guard (option no. 908-1) onpage 97 added in Installation chapter.

New DANGER! added in section Manually releasing the brakes onpage 70.

Restricting working range with software added in section Mechanicallyrestricting the working range of axis 1 on page 87.

The sections describing Replacing motors axes 1 through 6 has beenupdated. Two new sections Removingmotors on page278 and Refittingmotors on page 286 replaces the older ones.

A

The following updates have been made in this revision: Missing text "type A" for armhousing 3HAC034549-005 added in chapter

Spare parts section Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 on page 352.

Wrist Foundry added in chapter Spare parts, sectionWrist unit (60 kg/45kg/20 kg) on page 358.

Motors in wrist as rebuilding parts added in section Rebuilding parts onpage 345.

How to adjust the play on motors axes 4-6 and on wrist added in sectionsReplacing motors, axes 4, 5 and 6 and Replacing wrist unit on page257.

Correction of required oil level, see Inspecting oil level, axis 1 gearboxon page 114.

In chapter Safety : Updated safety signal graphics for levels Danger and Warning, see

Safety signals in the manual on page 42. New safety labels on the manipulators, see Safety symbols on manipu-

lator labels on page 44. Revised teminology: robot replaced with manipulator.

B




Continued

DescriptionRevision

The following updates have been made in this revision: Added Installing an expansion container on page 98. A figure showing IRB 2600 removed in section Orienting and securing

the robot on page 73. Section Installation of Foundry Plus Cable guard (option no. 908-1) on

page 97 added. Section Start of robot in cold environments on page 101 updated. Interval for inspection of signal lamp added in section Maintenance

schedule on page 111. New design of frame added in sections Inspecting oil level, axis 1 gear-

box on page114 and Changing the oil, axis-1 gearbox on floor mountedrobots on page 150.

Figure showing required oil level added in section Inspecting oil level,axis 1 gearbox on page 114.

Inspection of oil level on suspended robot updated in section Inspectingoil level, axis 1 gearbox on page 114.

C

The following updates have been made in this revision: Added information about the bracket on the mechanical stop pin axis 1

has been updated in section Mechanically restricting the working rangeof axis 1 on page 87, Inspecting the mechanical stop pin, axis 1 onpage 137 and Replacing stop pin axis 1 on page 275

All information about Foundry Prime is removed from the manual. Thismanual now only contains information for a Standard IRB 4600. The in-structions for a IRB 4600 Foundry prime can be found in a separatemanual. For art. No. See References on page 10.

D




Continued

DescriptionRevision

The following updates have been made in this revision: A new block, about general illustrations, added in section How to read

the product manual on page 18. Figure and describing text edited for the stress forces. Also, the actual

values of the stress forces are updated. See Loads on foundation, roboton page 59.

The difference in weight between the different robot variants is minor,therefor the weight specification for the robot is simplified. See Weight,robot on page 58.

Removed Foundry from table with protection classes. See Protectionclasses, robot on page 60.

Additional information about software adjustments when suspendingrobot, new section Setting the system parameters for a suspended roboton page 76.

Note about fan cabling added in the cable list. See Robot cabling andconnection points on page 102.

Note about ambient temperature deleted from the maintenance schedule.See Maintenance schedule on page 111.

Changed information about the robot position when removing motor.See Removing motors on page 278.

Additional instructions for how to adjust the play of axes 4, 5 and 6 mo-tors. See Adjusting the play of axis 4, 5 and 6 motors on page 296.

Additional step about removing/refitting axis 1 motor when replacing theaxis 1 gearbox. Also added information about guide pins. SeeReplacinggearbox axis 1 on page297. Also minor additions concerning the matingof gearbox and motor, in all such instructions.

New section about calibration movement directions for axes is added,see Calibration movement directions for all axes on page 325.

New section about how to perform a rough calibration of each robot axisis added, see Updating revolution counters on page 326.

New section about how to check the calibration position is added, seeChecking the calibration position on page 328.

Spare part number for tubular shaft unit is corrected, see Spare parts,upper arm -40/2.55 on page352 and Spare parts, upper arm -20/2.50 onpage 352.

Additional information about lifting accessories and how to attach themto the upper arm of the robot, see Attaching the lifting accessories tothe upper arm on page 247.

Additional information in the procedure for replacing the base with im-proved lifting instruction etc., see Replacing the base on page 232.

Changed type of oil in axes 1, 3 and 4 gearboxes. See Type of lubricationin gearboxes on page 148.

E




Continued

DescriptionRevision

The following updates have been made in this revision: Corrected measurement that belong to figure xx0300000187, when fitting

tools for measuring the play of axis 5, see Measuring the play, axis 5 onpage 262.

Deleted the spare part number for harnesses in Lower arm and frameon page350 and instead inserted a reference to theElectrical connectionson page 361.

Corrected the spare part numbers for cable harnesses, see Electricalconnections on page 361.

Added information about releasing the motor brakes in order to set theweight of different axes onto lifting accessories, see Replacing thecomplete upper arm on page242, Replacing gearbox axis 3 on page311and Replacing gearbox axis 2 on page 303.

Changed the instruction for how to replace the axes 2 and 3 gearboxeswithout having to remove the cable harness, see Replacing gearboxaxis 3 on page 311 and Replacing gearbox axis 2 on page 303.

Added safety information about preventing roundslings from slidingwhen lifting the upper arm tube, see Replacing complete tubular shaftunit on page 251.

Added information about removing painting, if any, from assembly sur-faces when replacing gearboxes and motors.

Added tip to speed up the draining of axis 4 gearbox, see Changing theoil, axis-4 gearbox on page 172.

Added information about o-ring and made other minor approvements tothe instruction for replacing wrist unit, see Replacing wrist unit onpage 257.

Added information about disconnecting the battery cable when removingthe cable harness, seeRemoving the complete cable harness on page195.

Added a funnel to equipment list, see Changing the oil, axis-3 gearboxon page 166.

Added Profibus to the section about connections to extra equipment,see Customer connection on robot on page 104.

Some general tightening torques have been changed/added, see updatedvalues in Screw joints on page 337.

The method of changing the axis-1 gearbox oil in suspended robots isimproved, see the new section Changing the oil, axis-1 gearbox onsuspended robots on page 156.

Added spare part number for type B gearbox (axis 3), see Upper armIRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 on page 352.

Added WARNING - Safety risks during handling of batteries on page54.

F

The following updates have been made in this revision: Cable harness for Profibus is added to the spare part list, see Electrical

connections on page 361. Article number for guide sleeves is added. Information about the type and amount of oil has been removed from

the manual and can now be found in the Technical reference manu-al - Lubrication in gearboxes, see References on page 10.

Type C is added throughout the manual. Valid for other designs than type C: Information about oil plug sealing

washer on the axis-1 and axis-2 gearbox is changed. The spare partnumber is added.

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

G




Continued

DescriptionRevision

The following updates have been made in this revision: Spare part numbers are corrected for the lower arm, see Type C on

page350 and Rebuilding parts on page345, and for motors, see Motors -Type C on page 365.

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

Section describing inspection of oil level in axis-1 gearbox for suspendedrobots is clarified, see Inspecting oil level, axis 1 gearbox on page 114.

H



Continued

Product documentation, IRC5Categories 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 IRC5 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 orelectrical connections).

Maintenance (descriptions of all required preventive maintenance proceduresincluding intervals and expected life time of parts).

Repair (descriptions of all recommended repair procedures including spareparts).

Calibration.

Decommissioning.

Reference information (safety standards, unit conversions, screw joints, listsof tools ).

Spare parts list with exploded views (or references to separate spare partslists).

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, IRC5

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, systemparameters, 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, IRC5

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.

Note/IllustrationAction

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 19.

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 20.

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 42.


1 Safety

1.1 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 Safety

1.2.1 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 Safety

1.2.2 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 sothat the manipulator can be stopped quickly.

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

Those who install the manipulator must have the appropriate training for theequipment 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 Make sure that no one else can turn on the power to the controller and

manipulator while you are working with the system. A good method is toalways lock the main switch on the controller cabinet with a safety lock.

Safety zones, which must be crossed before admittance, must be set up infront of the manipulator's working space. Light beams or sensitive mats aresuitable devices.



1 Safety


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

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 themanipulator 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



1 Safety


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!


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!


1 Safety


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 Safety

1.2.3.2 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 Safety

1.2.3.3 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 hydraulicsystems before starting to repair them.

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

All pipes, hoses, and connections have to be checked regularly for leaks anddamage. 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 Safety

1.2.3.4 Safety risks related to pneumatic/hydraulic systems

1.2.3.5 Safety risks with pressure relief valve

IntroductionThe pressure relief valve must be kept clean and open, for it to be able to functionproperly.

Safety risksThe pressure relief valve is a vital part preventing too much air pressure being builtup inside the manipulator. If too much air pressure has been built up, there is arisk of personal injury and mechanical damage.


1 Safety

1.2.3.5 Safety risks with pressure relief valve

1.2.3.6 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 theapplicable 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 Safety

1.2.3.6 Safety risks during operational disturbances

1.2.3.7 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 robots working space.

Make sure that one else can turn on the power to the controller andmanipulator while you are working with the system. A good method is toalways lock the main switch on the controller cabinet with a safety lock.

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 againstreconnection

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 forthe machining process.

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

Additional connections.



1 Safety


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. 230VAC).

See chapter Installation and commissioning on page 57.

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 Safety


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 Safety

1.2.4.1 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 Safety

1.2.4.2 Fire extinguishing

1.2.4.3 Emergency release of the manipulators 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 70.

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 Safety

1.2.4.3 Emergency release of the manipulators 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 Safety

1.2.4.4 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 Safety

1.2.4.5 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 assoon as there is no need for the manipulator to move.

Anyone entering the manipulator working space must always bring theFlexPendant 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 Safety

1.2.4.6 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 manipulators 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 manipulators 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 35.

To prevent anyone else from taking control of the manipulator, always puta safety lock on the cell door and bring the enabling device with you whenentering the working space.

WARNING

NEVER, under any circumstances, stay beneath any of the manipulators 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 manipulators working range.


1 Safety

1.2.4.7 Work inside the manipulator's working range

1.2.4.8 Signal lamp (optional)

DescriptionA signal lamp with a yellow fixed light can be mounted on the manipulator, as asafety device.

FunctionThe lamp is active in MOTORS ON mode.

Further informationFurther information about the MOTORS ON/MOTORS OFF mode may be found inthe product manual for the controller.


1 Safety

1.2.4.8 Signal lamp (optional)

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 Safety


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 Safety


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 Safety


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 Safety


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 44.

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 Safety


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.



1 Safety


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



1 Safety


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.



1 Safety


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.


1 Safety


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 Safety

1.3.3 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. Mechanical stops will not always stop themovements of the manipulator completely.


1 Safety

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

1.3.5 WARNING - The brake release buttons may be jammed after service work

DescriptionThe brake release unit has push-buttons for the brake release of each axis motor.When service work is performed inside the SMB recess that includes removal andrefitting of the brake release unit, the brake release buttons may be jammed afterrefitting.

DANGER

If the power is turned on while a brake release button is jammed in depressedposition, the affected motor brake is released! This may cause serious personalinjuries and damage to the manipulator.

EliminationTo eliminate the danger after service work has been performed inside the SMBrecess, follow the procedure below.

Action

Make sure the power is turned off.1

Remove the push-button guard, if necessary.2

Check the push-buttons of the brake release unit by pressing them down, one by one.3Make sure none of the buttons are jammed in the tube.

If a button gets jammed in the depressed position, the alignment of the brake releaseunit must be adjusted so that the buttons can move freely in their tubes!

4


1 Safety

1.3.5 WARNING - The brake release buttons may be jammed after service work

1.3.6 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, Single Cabinet Controller

Note/illustrationAction

xx0600002782

Switch off the main switch on the controllercabinet.

1

A: Main switch

Elimination, Dual Cabinet Controller

Note/illustrationAction

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 Safety

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

1.3.7 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.

A

xx1300000856

Wrist strap buttonA


1 Safety

1.3.7 WARNING - The unit is sensitive to ESD!

1.3.8 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 58.

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 Safety

1.3.8 WARNING - Safety risks during handling of batteries

1.3.9 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 Safety


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 Safety


Continued

2 Installation and commissioning2.1 Introduction

GeneralThis chapter contains information for installing the IRB 4600 at the working site.

More detailed technical data can be found in the Product specification for the IRB4600, 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 chapter Safety on page19 before performing any installationwork.

Note

If the IRB 4600 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



2.1 Introduction

2.2 Unpacking

2.2.1 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 58

2

If the robot is not installed directly, it must be stored as described in: Storage conditions, robot on page 60

3

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

Operating conditions, robot on page 60

4

Before taking the robot to its installation site, make sure that the site conforms to: Loads on foundation, robot on page 59 Protection classes, robot on page 60 Requirements, foundation on page 60

5

Before moving the robot, please observe the stability of the robot: Risk of tipping/stability on page 65

6

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

On-site installation on page 66

7

Install required equipment, if any. Installation of signal lamp (option) on page 85

8

Weight, robotThe table shows the weight of the robot.

WeightRobot model

440 kgIRB 4600

Note

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




2.2.1 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

7790 N3940 NForce xy

4350 6360 N4350 2460 NForce z

14090 Nm6850 NmTorque xy

2960 Nm1610 NmTorque z

Suspended

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

7790 N3940NForce xy

-4350 6360 N-4350 2460NForce z



2 Ins

abb product manual irb4600

Documents

safety risks

safety actions

general safety information

safety fence dimensions

abb roboticsproduct

caution hot parts

live electric parts

consequential damages