abb product specification irb4600

ABB Robotics

Product specificationIRB 4600

Trace back information:Workspace R13-1 version a11Checked in 2013-04-15Skribenta version 4.0.006

Product specification

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

Document ID: 3HAC032885-001

Revision: M

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 contents7Overview of this specification ..........................................................................................................

91 Description

91.1 Structure .........................................................................................................91.1.1 Introduction to Structure ...........................................................................

141.1.2 Different robot versions ............................................................................181.2 Standards ........................................................................................................181.2.1 Applicable safety standards ......................................................................201.3 Installation .......................................................................................................201.3.1 Introduction to Installation .........................................................................211.3.2 Operating requirements ............................................................................221.3.3 Mounting the manipulator .........................................................................251.4 Calibration and references ..................................................................................251.4.1 Fine calibration .......................................................................................261.4.2 Absolute Accuracy calibration ...................................................................281.5 Robot load and load diagrams .............................................................................281.5.1 Introduction to Robot load and load diagrams ...............................................291.5.2 Load diagrams ........................................................................................

361.5.3 Maximum load and moment of inertia for full and limited axis 5 (centerlinedown)

movement ..............................................................................................381.5.4 Wrist torque ...........................................................................................391.6 Mounting equipment ..........................................................................................391.6.1 Information about mounting equipment .......................................................461.7 Maintenance and Troubleshooting ........................................................................461.7.1 Introduction to Maintenance and Troubleshooting .........................................471.8 Robot Motion ....................................................................................................471.8.1 Introduction to Robot Motion .....................................................................491.8.2 Performance according to ISO 9283 ............................................................501.8.3 Velocity .................................................................................................511.8.4 Stopping distance/time .............................................................................521.9 Cooling fan for axis 1-2 motor ..............................................................................531.10 Customer connections .......................................................................................531.10.1 Introduction to Customer connections .........................................................

552 Specification of variants and options

552.1 Introduction to variants and options ......................................................................562.2 Manipulator ......................................................................................................632.3 Floor cables .....................................................................................................642.4 Process ...........................................................................................................652.5 Documentation .................................................................................................

673 Accessories

673.1 Introduction to accessories .................................................................................

69Index

3HAC032885-001 Revision: M 5 Copyright 2009-2013 ABB. All rights reserved.

Table of contents

This page is intentionally left blank

Overview of this specificationAbout this product specification

It describes the performance of themanipulator or a complete family of manipulatorsin terms of:

The structure and dimensions prints

The fulfillment of standards, safety and operating requirements

The load diagrams, mounting or extra equipment, the motion and the robotreach

The specification of variants and options available

UsageProduct specifications are used to find data and performance about the product,for example to decide which product to buy. How to handle the product is describedin the product manual.

UsersThis manual is intended for:

Product managers and personnel

Sales and Marketing personnel

Order and Customer Service personnel

References

Document IDReference

3HAC022349-001Product specification - Controller software IRC5

3HAC041344-001Product specification - Controller IRC5 with FlexPendant

3HAC024534-001Product specification - Robot user documentation

3HAC033453-001Product manual - IRB 4600

Revisions

DescriptionRevision

First edition-

- Updated/Corrected Load diagramA

- Corrected working range floor mountedB

- General updates and correctionsC

- Corrected chapter: Mounting and BushingsD

- Foundry Plus 2E

- Foundry Plus 2 updateF

- Text for Standards updated, minor changesG

- Foundry Prime 2 added + minor correctionsH

Continues on next page3HAC032885-001 Revision: M 7


Overview of this specification

DescriptionRevision

Table for ambient temperature adjusted Value added to drawing, Mounting suface and bushings Minor corrections

J

Machinery directive updatedK

General updates and minor corrections Foundry Prime 2 added

L

General updates and minor correctionsM

8 3HAC032885-001 Revision: M Copyright 2009-2013 ABB. All rights reserved.

Overview of this specification

Continued

1 Description1.1 Structure

1.1.1 Introduction to Structure

Robot familyThe IRB 4600 series is ABB Robotics pioneer of the new sharp generation withenhanced and new capabilities. The design has been optimized tomake it superiorfor the targeted applications. The IRB 4600 will focus on further expansion inmaterial handling, machine tending, laser- and water jet cutting, dispensing,measuring, assembly and welding applications.

Operating systemThe robot is equipped with the IRC5 controller and robot control software,RobotWare. RobotWare supports every aspect of the robot system, such asmotioncontrol, development and execution of application programs, communication etc.See Product specification - Controller IRC5 with FlexPendant.

SafetySafety standards valid for complete robot, manipulator and controller.

Additional functionalityFor additional functionality, the robot can be equipped with optional software forapplication support - for example gluing and welding, communication features -network communication - and advanced functions such as multitasking, sensorcontrol etc. For a complete description on optional software, see the Productspecification - Controller software IRC5.



1 Description


Foundry Plus 2The Foundry Plus option is designed for harsh environments where the robot isexposed to sprays of coolants, lubricants and metal spits that are typical for diecasting applications or other similar applications. Typical applications are sprayinginsertion and part extraction of die-castingmachines, handling in sand casting andgravity casting, etc. Special care must be taken in regard to operational andmaintenance requirements for applications in foundry are as well as in otherapplications areas. Please contact ABB Robotics Sales organization if in doubtregarding specific application feasibility for the Foundry Plus protected robot. TheFoundry Plus robot is painted with two-component epoxy on top of a primer forcorrosion protection. To further improve the corrosion protection additional rustpreventive are applied to exposed and crucial areas, e.g. has the tool flange aspecial preventive coating. Although, continuous splashing of water or other similarrust formation fluids may case rust attach on the robots unpainted areas, joints,or other unprotected surfaces. Under these circumstances it is recommended toadd rust inhibitor to the fluid or take other measures to prevent potential rustformation on the mentioned. The entire robot is IP67 compliant according to IEC60529 - from base to wrist, which means that the electrical compartments aresealed against liquid and solid contaminants. Among other things all sensitiveparts are better protected than the standard offer.

Selected Foundry Plus/Foundry Plus 2 features:

Improved sealing to prevent penetration into cavities to secure IP67

Additional protection of cabling and electronics

Special covers protecting cavities

Special connectors

Nickel coated tool flange (Foundry Plus 2)

Rust preventives on screws, washers and unpainted/machined surfaces

The Foundry Plus robot can be cleaned with appropriate washing equipmentaccording to product manual. Appropriate cleaning and maintenance are requiredto maintain the Foundry Plus 2 protection, for example can rust preventive bewashed off with wrong cleaning method.

Continues on next page10 3HAC032885-001 Revision: M


1 Description


Continued

Foundry Prime 2The robot version Foundry Prime is designed for water jet cleaning of casts andmachined parts, and similar very harsh, but proven robotic application environments.Applicability in other applications cannot be guaranteed without prior testing,previous experience or professional judgment by ABB. Please contact ABBRoboticsSales organization if in doubt regarding specific application feasibility. Themanipulator can withstand surrounding solvent based detergents which must beapproved by ABB. In addition, the manipulator can withstand indirect spray fromjet pressure (max. 600 bar) and 100% humidity (gaseous mixture only). Themanipulator can work in an environment with a cleaning bath temperature < 60o

C, typically used in a washing application with moderate robot speed. Surroundingtemperate cannot be higher than specified for the option. If fluids that may causerust formation, for example water, are continuous splashing the robot or are usedin the vicinity of the robot it is strongly recommended to add rust inhibitor to thefluid or take other measures to prevent potential rust formation on the robotsunpainted areas, joints, or other unprotected, surfaces. The robot is protected bywell-proven sealings for gears and bearings, pressurized motors and electroniccompartment, and detergent resistant painting system in three layers (two layerepoxy paint under a protective layer of clear coat). Non painted surfaces has rustpreventive coating (Mercasol), and motors (IRB 4400) are sealed with a sealingcompound.As the robot is designed for very harsh environments, an extendedservice and maintenance program is required. Special care must be taken whenreplacing parts or performing other maintenance and service that breaks the paintsurface as the paint surface act as a protective barrier. For detailed information ofthe maintenance program, see chapter Maintenance in the Product Manual. It ishighly recommended to sign a Service Agreement with ABB due to difficult andsevere environmental conditions. The Foundry Prime robot can be cleaned withappropriate washing equipment according to product manual. Appropriate cleaningandmaintenance are required tomaintain the Foundry Prime protection, for examplecan the rust preventive be washed off with wrong cleaning method.

DetergentsGeneral detergent requirements:

Washing detergent with max pH

Please contact your local ABB organization for an updated list of approved washingdetergents.

Available robot versionsThe protection, Foundry Prime is only available for robot versions IRB 4600-60/2.05.Please contact your local ABB organization for an updated list of approved washingdetergents. See chapter Specification of Variants and Options for options notselectable together with Foundry Prime

xx1000000389

DescriptionPosDescriptionPos

Axis 2BAxis 1A

Axis 4DAxis 3C

Axis 6FAxis 5E



1 Description


Continued

Manipulator axes

xx0800000431


Axis 2BAxis 1A

Axis 4DAxis 3C

Axis 6FAxis 5E


1 Description


Continued

1.1.2 Different robot versions

GeneralThe IRB 4600 is available in four versions and all versions can be floor mounted,inverted or tilted (up to 15 degrees around the Y-axis).

Reach (m)Handling capacity (kg)Robot type

2.05 m60 kgIRB 4600

2.05 m45 kgIRB 4600

2.55 m40 kgIRB 4600

2.50 m20 kgIRB 4600

Manipulator weight

WeightRobot type

425 kgIRB 4600-60/2.05

425 kgIRB 4600-45/2.05

435 kgIRB 4600-40/2.55

412 kgIBB 4600-20/2.50

Other technical data

NoteDescriptionData

xx0800000420



1 Description


Continued

Dimensions IRB 4600-60(45)/2.05 and IRB 4600-40/2.55

xx0800000430

DescriptionPos

R 400 Minimum turning radius of axis 1A

R 138 Minimum turning radius of axis 4B

FEDCVariant

960 mm1276 mm900 mm1727 mmIRB 4600-60/2.05

960 mm1276 mm900 mm1727 mmIRB 4600-45/2.05

1270 mm1586 mm1095 mm1922 mmIRB 4600-40/2.55



1 Description


Continued

Dimensions IRB 4600-20/2.50

CL

xx0800000428

DescriptionPos

R 98 Minimum turning radius of axis 4A

For all other dimensions see Figure 3B


1 Description


Continued

1.2 Standards

1.2.1 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, andmotionnomenclatures

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 60529

i There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times aredocumented.

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



1 Description


Other standards

DescriptionStandard

Safety requirements for industrial robots and robot systemsANSI/RIA R15.06

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)


1 Description


Continued

1.3 Installation

1.3.1 Introduction to Installation

GeneralAll versions of IRB 4600 are designed for floor mounting, tilted (up to 15 degrees,also valid for inverted robot) or inverted mounting. Depending on the robot version,an end effector with max. weight of 20 or 60 kg including payload, can be mountedon the tool flange (axis 6). See Load diagrams on page 29.

Extra loadsExtra loads, which are included in the load diagrams, can bemounted on the upperarm. An extra load of 35 kg can also be mounted on the frame of axis 1. SeeInformation about mounting equipment on page 39

Working range limitationsTheworking range of axis 1 can be limited bymechanical stops as option. ElectronicPosition Switches can also be used on all axes for position indication of themanipulator.


1 Description

1.3.1 Introduction to Installation

1.3.2 Operating requirements

Protection standardsStandard IP67 and Foundry Plus IP67.

Explosive environmentsThe robot must not be located or operated in an explosive environment.

Ambient temperature

TemperatureStandard/OptionDescription

+ 5C a) (41F) to + 45C (113F)StandardManipulator during operation

See Product specification - ControllerIRC5 with FlexPendant

Standard/OptionFor the controller

- 25C (- 13F) to + 55C (131F)StandardComplete robot during trans-portation and storage

up to + 70C (158F)StandardFor short periods (not exceed-ing 24 hours)

a) At low environmental temperature < 10o C is, as with any other machine, awarm-up phase recommended to be run with the robot. Otherwise there is a riskthat the robot stops or run with lower performance due to temperature dependentoil- and grease viscosity.

Relative humidity

Relative humidlyDescription

Max. 95% at constant temperatureComplete robot during operation, transportation andstorage


1 Description

1.3.2 Operating requirements

1.3.3 Mounting the manipulator

Maximum loadMaximum load in relation to the base coordinate system

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

14090 Nm6850 NmTorque xy

2960 Nm1610 NmTorque z

ABB Roboti cs Products A B

xx0800000435



1 Description


xx0800000436

Note regarding Mxy and FxyThe bending torque (Mxy) can occur in any direction in the XY-plane of the basecoordinate system.The same applies to the transverse force (Fxy).

Fastening holes robot base

xx0800000271

Attachment bolts, specificationThe table below specifies required bolts and washers for securing the robot atinstallation site

DescriptionSpecification

M16 x 60 (installation directly on foundation)M16 x 70/80(installation on foundation or base plate, using guidingsleeves)

Attachment bolts, 6 pcs

17 x 30 x 3Washers, 6 pcs

Quality 8.8Quality

200 NmTightening torque

Note

AbsAcc performance, the chosen guide holes according to Figure above arerecommended



1 Description


Continued

Mounting surface and bushings

125

xx0800000415

DescriptionPos

Surface treatment, ISO 2081 Fe/Zn 8 c2, Guide bushingA

View DB

3x common zoneC


1 Description


Continued

1.4 Calibration and references

1.4.1 Fine calibration

GeneralFine calibration is made using the Calibration Pendulum, see Operatingmanual - Calibration Pendulum.

xx0800000437


Axis 2BAxis 1A

Axis 4DAxis 3C

Axis 6FAxis 5E

Calibration

PositionCalibration

All axes are in zero positionCalibration of all axes

Axis 1 and 2 in zero positionCalibration of axis 1 and 2

Axis 3 to 6 in any position

Axis 1 in zero positionCalibration of axis 1

Axis 2 to 6 in any position


1 Description

1.4.1 Fine calibration

1.4.2 Absolute Accuracy calibration

GeneralRequires RobotWare option Absolute Accuracy, please see Product specification- Controller software IRC5 for more details.

The calibration conceptAbsolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absoluteaccuracy of better than 1mm in the entire working range (working range of bendingbackward robots, for example IRB 4600, are limited to only forward positions).

Absolute accuracy compensates for:

Mechanical tolerances in the robot structure

Deflection due to load

Absolute accuracy calibration is focusing on positioning accuracy in the cartesiancoordinate system for the robot. It also includes load compensation for deflectioncaused by the tool and equipment. Tool data from robot program is used for thispurpose. The positioning will be within specified performance regardless of load.

Calibration dataThe user is supplied with robot calibration data (compensation parameter file,absacc.cfg) and a certificate that shows the performance (Birth certificate). Thedifference between an ideal robot and a real robot without AbsAcc may reach upto 8mm, resulting frommechanical tolerances and deflection in the robot structure.



1 Description


Absolute Accuracy optionAbsolute Accuracy option is integrated in the controller algorithms for compensationof this difference and does not need external equipment or calculation.AbsoluteAccuracy is a RobotWare option and includes an individual calibration of the robot(mechanical arm).Absolute Accuracy is a TCP calibration in order to Reach (m) agood positioning in the Cartesian coordinate system.

xx0900000073

Production dataTypical production data regarding calibration are:

Positioning accuracy (mm)Robot

% Within 1 mmMaxAverage

981,000,50IRB 4600-60/2.05

1000.800.40IRB 4600-45/2.05

981.000,40IRB 4600-40/2.55

1000.800.40IRB 4600-20/2.50


1 Description


Continued

1.5 Robot load and load diagrams

1.5.1 Introduction to Robot load and load diagrams

Information

WARNING

It is very important to always define correct actual load data and correct payloadof the robot. Incorrect definitions of load data can result in overloading of therobot.

If incorrect load data and/or loads are outside load diagram is used the followingparts can be damaged due to overload:

motors

gearboxes

mechanical structure

WARNING

In the robot system is the service routine LoadIdentify available, which allowsthe user to make an automatic definition of the tool and load, to determine correctload parameters. Please seeOperating Manual - IRC5 with FlexPendant, art. No.3HAC16590-1, for detailed information.

WARNING

Robots running with incorrect load data and/or with loads outside diagram, willnot be covered by robot warranty.

GeneralThe load diagrams include a nominal payload inertia, J0 of 2.5 kgm

2 for IRB4600-60/2.05, -45/2.05, -40/2.55 and 0.06 kgm2 for IRB 4600-20/2.50, and an extraload of 15 kg at the upper arm housing for IRB 4600-60/2.05, -45/2.05, -40/2.55 and10 kg for IRB 4600-20/2.50.

At different arm load, payload and moment of inertia, the load diagram will bechanged.

Control of load case by "RobotLoad"For an easy check of a specific load case, use the calculation program ABBRobotLoad. Please contact your local ABB organization.


1 Description

1.5.1 Introduction to Robot load and load diagrams

1.5.2 Load diagrams

IRB 4600 - 60/2.05

xx0800000448



1 Description

1.5.2 Load diagrams

IRB 4600 - 60/2.05 "Vertical wrist" (+-10)

xx0900000070

For wrist down (0 deviation from the vertical line).

Description

73 kgMax load

0,216 mZmax

0,028 mLmax



1 Description

1.5.2 Load diagrams

Continued

IRB 4600 - 45/2.05

L (m)xx0900000069

Load diagram "Vertical wrist" is not available for IRB 4600-45/2.05.



1 Description

1.5.2 Load diagrams

Continued

IRB 4600 - 40/2.55

0,000,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

1,10

1,20

0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80

40kg

30kg

20kg

10kg

5kg

Z (

m)

L (m)

xx0800000447



1 Description

1.5.2 Load diagrams

Continued


xx0900000068


Description

47 kgMax load

0,157 mZmax

0,044 mLmax



1 Description

1.5.2 Load diagrams

Continued

IRB 4600 - 20/2.50

L (m)xx0900000071



1 Description

1.5.2 Load diagrams

Continued


Z (m

)

xx0900000067


Description

23 kgMax load

0,1 mZmax

0,06 mLmax


1 Description

1.5.2 Load diagrams

Continued

1.5.3 Maximum load andmoment of inertia for full and limited axis 5 (centerlinedown)movement

Information

Note

Total load given as: Mass in kg, center of gravity (Z and L) in meter and momentof inertia (Jox Joy Joz) in kgm

2 . L=sqr(x2 + y2), see Figure 18

Full movement of axis 5

Maximum moment of inertiaRobot TypeAxis

Ja5 = Load x ((Z + 0,1352 + L2 ) + max (J0x, J0y) 30 kgm260/2.05, 45/2.055

Ja5 = Load x ((Z + 0,1352 + L2 ) + max (J0x, J0y) 20 kgm240/2.55

Ja5 = Load x ((Z + 0,085)2 + L2 ) + max (J0x, J0y) 2 kgm220/2.50

Ja6 = Load x L2 + J0Z 20 kgm260/2.05, 45/2.056

Ja6 = Load x L2 + J0Z 15 kgm240/2.55

Ja6 = Load x L2 + J0Z 1 kgm220/2.50

xx0800000458

DescriptionPos

Center of gravityA

Description

Max. moment of inertia around the X, Y and Z axes at centerof gravity.

Jox, Joy, Joz



1 Description

1.5.3 Maximum load and moment of inertia for full and limited axis 5 (centerlinedown) movement

Limited axis 5, center line down

Maximum moment of inertiaRobot TypeAxis

Ja5 = Load x ((Z + 0,135)2 + L2 ) + max (J0x, J0y) 30 kgm260/2.05, 45/2.055

Ja5 = Load x ((Z + 0,135)2 + L2 ) + max (J0x, J0y) 20 kgm240/2.55

Ja5 = Load x ((Z + 0,0852 + L2 ) + max (J0x, J0y) 2 kgm220/2.50

Ja6 = Load x L2 + J0Z 20kgm260/2.05, 45/2.056

Ja6 = Load x L2 + J0Z 15 kgm240/2.55

Ja6 = Load x L2 + J0Z 1 kgm220/2.50

xx0800000459

DescriptionPos

Center of gravityA

Description

Max. moment of inertia around the X, Y and Z axes at centerof gravity.

Jox, Joy, Joz


1 Description

1.5.3 Maximum load and moment of inertia for full and limited axis 5 (centerlinedown) movement

Continued

1.5.4 Wrist torque

Maximum torque due to payloadThe table below shows the maximum permissible torque due to payload:

Note

The values are for reference only, and should not be used for calculating permittedload offset (position of center of gravity) within the load diagram, since thosealso are limited by main axes torques as well as dynamic loads. Also arm loadswill influence the permitted load diagram, please contact your local ABBorganization.

Max torque valid atload

Max wrist torqueaxis 6

Max wrist torqueaxis 4 and 5

Robot type

60 kg105 Nm200 NmIRB 4600 - 60/2.05

45 kg77 Nm145 NmIRB 4600 - 45/2.05

40 kg68 Nm132 NmIRB 4600 - 40/2.55

20 kg15 Nm37 NmIRB 4600 - 20/2.50


1 Description

1.5.4 Wrist torque

1.6 Mounting equipment

1.6.1 Information about mounting equipment

GeneralExtra loads can be mounted on the wrist, the upper arm housing and on the frame.Definitions of load areas and permitted load are shown in. The center of gravity ofthe extra load shall be within the marked load areas. The robot is supplied withholes for mounting of extra equipment. (See figures in Holes for mounting of extraequipment on page 40.)

xx0800000434

Max loadLoad areaRobot DA+CCBA

35 kg15 kg15 kg5 kga15 kgIRB 4600 - 60/2.05

35 kg15 kg15 kg5 kgb15 kgIRB 4600 - 45/2.05

35 kg15 kg15 kg5 kgc15 kgIRB 4600 - 40/2.55



1 Description


Max loadLoad areaRobot DA+CCBA

35 kg10 kg10 kg1 kg10 kgIRB 4600 - 20/2.50

a. Payload + B max 60kg

b. Payload + B max 45kg

c. Payload + B max 40kg

Holes for mounting of extra equipment

J

CL Axis 2

0,4

125 75

11

0

3x M8 16C-C

0,51

6)

220

13

8

65 (

3x M

8

50

27

6

4x M8 16

19

0 (

4xM

8 1

6)

xx0800000414

D

0,3

1665

130

3x M8

19

0 8

0

E

0,3

19

0

110

80

2x M8 16

xx0800000412



1 Description


Continued

xx0800000419

xx0800000418



1 Description


Continued

xx0800000416

xx0800000417

xx0800000421



1 Description


Continued

xx0800000409

xx0800000408

xx0800000411



1 Description


Continued

IRB 4600-40/2.55 and IRB 4600-20/2.50

xx0800000423

IRB 4600 60(45)/2.05

xx0800000425



1 Description


Continued

Tool flangeIRB 4600-20/2.50

xx0800000449

IRB 4600-60/2.05, IRB4600-45/2.05 and IRB 4600-40/2.55

xx0800000450

For fastening of Gripper tool flange to Robot tool flange every other one of the screw holes for 6 screws,

quality class 12.9 shall be used. Min. 15 mm free threads lenght.


1 Description


Continued

1.7 Maintenance and Troubleshooting

1.7.1 Introduction to Maintenance and Troubleshooting

GeneralThe robot requires only minimum maintenance during operation. It has beendesigned to make it as easy to service as possible:

Maintenance-free AC motors are used.

Oil is used for the gear boxes.

The cabling is routed for longevity, and in the unlikely event of a failure, itsmodular design makes it easy to change.

MaintenanceThemaintenance intervals depend on the use of the robot, the requiredmaintenanceactivities also depends on selected options. For detailed information onmaintenanceprocedures, see Maintenance section in the Product Manual.


1 Description

1.7.1 Introduction to Maintenance and Troubleshooting

1.8 Robot Motion

1.8.1 Introduction to Robot Motion

IRB 4600

Range of movementType of motionAxis

+ 180 to - 180Rotation Motion1

+ 150 to - 90Arm motion2

+ 75 to - 180Arm motion3

+ 400 to - 400 DefaultRotation motion4+ 201 rev.a to - 201 rev. Max.c

+ 120 to - 125 bBend motion5

+ 400 to - 400 DefaultTurn motion6+ 241 rev.a to - 241c rev. Max.d

a. rev. = Revolutions.

b. IRB 4600-20/2.50, + 120 to -120.

c. Valid for IRB 4600-20/2.50 is + 183 to - 183 rev. d. The default working range foraxis 4 and axis 6 can be extended by changing parameter values in the software.Option 610-1 "Independent axis" can be used for resetting the revolution counterafter the axis has been rotated (no need for "rewinding" the axis)



1 Description


Working range, floor mounted

E F

DC

BA

xx0900000119

Pos. FPos. EPos. DPos. CPos. BPos. AVariant

2051 mm1701 mm593 mm1028 mm1260 mm2371 mmIRB 4600-60/2.05





1 Description


Continued

1.8.2 Performance according to ISO 9283

GeneralAt rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISOtest plane, 1m cube with all six axes in motion

The figures for AP, RP, AT and RT are measured according to figure below.

xx0800000424


Programmed pathEProgrammed positionA

Actual path at program executionDMean position at programexecution

B

Max deviation from E to average pathATMean distance from pro-grammed position

AP

Tolerance of the path at repeatedprogram execution

RTTolerance of position B at re-peated positioning

RP

IRB 4600Description

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

0.050.060.050.06Pose repeatability, RP (mm)

0.030.020.020.02Pose accuracy, APa (mm)

0.170.280.130.46Linear path repeatability, RTb(mm)

0.930.570.480.74Linear path accuracy, ATb (mm)

0.190.400.130.10Pose stabilization time, (PSt) towithin 0.4 mm of the position (s)

a.AP according to the ISO test above, is the difference between the reached position(position manually modified in the cell) and the average position obtained duringprogram execution

b. The values for RT and AT are measured at a velocity of 250 mm/s

The above values are the range of average test results from a number of robots.


1 Description

1.8.2 Performance according to ISO 9283

1.8.3 Velocity

Maximum axis speed

Axis 6Axis 5Axis 4Axis 3Axis 2Axis 1Robot Type

360 /s250 /s250 /s175 /s175 /s175 /sIRB 4600 - 60/2.05

360 /s250 /s250 /s175 /s175 /s175 /sIRB 4600 - 45/2.05

360 /s250 /s250 /s175 /s175 /s175 /sIRB 4600 - 45/2.55

500 /s360 /s360 /s175 /s175 /s175 /sIRB 4600 - 20/2.50

There is a supervision function to prevent overheating in applications with intensiveand frequent movements.

Axis Resolution0.001 to 0.005.


1 Description

1.8.3 Velocity

1.8.4 Stopping distance/time

Stopping distance/time for all IRB4600 variantsStopping distance/time for emergency stop (category 0), program stop (category1)and at mains power supply failure at max speed, max stretched out and max load,categories according to EN 60204-1. All results are from tests on one moving axis.All stop distances are valid for floor mounted robot, without any tilting.

Main power failureCategory 1Category 0Robot Type

BABABAAxis

0.7569.90.9483.70.5856.61IRB 4600-60/2.05

0.4740.40.6650.60.3430.32

0.3234.70.5543.40.3124.83

0.7569.00.8982.60.6355.71IRB 4600-45/2.05

0.4843.90.5049.00.4429.32

0.3941.00.3639.80.2520.73

1.0895.01.26110.00.7864.81IRB 4600-40/2.55

0.4939.00.8155.00.4630.52

0.3936.50.6459.80.3526.63

0.6263.60.8176.50.5649.61IRB 4600-20/2.50

0.3739.10.5746.80.3027.12

0.3027.10.4638.30.2219.73

Description

Distance in degreesA

Stop time (s)B


1 Description

1.8.4 Stopping distance/time

1.9 Cooling fan for axis 1-2 motor

Option 87-1, 88-1To be used to avoid overheating of motors and gears in applications with intensivemotion (high average speed and /or high average torque and/or short wait time)of axis 1 and/or axis 2.

Valid protection for cooling fan is IP54.

To determine the use of cooling fans for axis 1 and/or axis 2motor use the GearboxHeat Prediction Tool in RobotStudio. Reliable facts for the decision of need forfan or not will be achieved by entering the ambient temperature for a specific cycle.Please contact your local ABB organization.


1 Description

1.9 Cooling fan for axis 1-2 motor

1.10 Customer connections

1.10.1 Introduction to Customer connections

GeneralCustomer connections are options, the cables for them are integrated in the robotand the connectors are placed on the upper arm housing and at the base. OneUT0W71210SH06 connector (R2. CP(/CBUS)) and one UT0W71626H06 connector(R2.CS(/CP)). Corresponding connectors, R1.CP(/CBUS) and R1.CS(/CP) arelocated at the base.Hose for compressed air is also integrated into the manipulator.There is an (M16-3/8 hose) inlet at the base and an outlet on the rear part of theupper arm.

(C) (A) (B)xx0800000426

ValueNumberDescriptionConnectionPos

300 V, 2 A4aCustomer powerR2.CPA

50 V, 0.5 A23Customer signalsR2.CSB

Inner hose diameter 9.5 mm1max 8 barAirC

Connectors when EtherNet, DeviceNet, PROFIBUS and Parallel communication,is chosen:

ValueNumberDescriptionConnectionPos

PROFINET, EtherNet/IPMultibus comm.R2.CBUSADeviceNet PROFIBUS

300 V, 2 A / 50 V, 0.5 A3 a / 6Cust. power/signalsR2.CP/CSB

Inner hose diameter 9.5 mm1max 8 barAirC

a. One protected ground included.


1 Description

1.10.1 Introduction to Customer connections

2 Specification of variants and options2.1 Introduction to variants and options

GeneralThe different variants and options for the IRB 4600 are described in the followingsections. The same option numbers are used here as in the specification form.

Related informationFor the controller see Product specification - Controller IRC5 with FlexPendant.

For the software options see Product specification - Controller software IRC5.



2.1 Introduction to variants and options

2.2 Manipulator

Variants

Handling capacity (kg) / Reach (m)IRB TypeOption

60/2.05IRB 4600435-84

45/2.05IRB 4600435-85

40/2.55IRB 4600435-86

20/2.50IRB 4600435-94

Manipulator color

DescriptionOption

The robot is painted in color ABB Orange.209-1

The robot is painted in white color.209-2

The manipulator is painted with the chosen RAL-color.209-4--192

Note

Notice that delivery time for painted spare parts will increase for none standardcolors.

Protection

DescriptionOption

Standard287-4




2.2 Manipulator

DescriptionOption

Foundry Plus 2287-3The Foundry Plus option is designed for harsh environments where the robotis exposed to sprays of coolants, lubricants and metal spits that are typicalfor die casting applications or other similar applications. Typical applicationsare spraying insertion and part extraction of die-casting machines, handlingin sand casting and gravity casting, etc. Special care must be taken in regardto operational and maintenance requirements for applications in foundry areas well as in other applications areas. Please contact ABB Robotics Salesorganization if in doubt regarding specific application feasibility for theFoundry Plus robot. The Foundry Plus robot is painted with two-componentepoxy on top of a primer for corrosion protection. To further improve thecorrosion protection additional rust preventive are applied to exposed andcrucial areas, e.g. has the tool flange a special preventive coating. Although,continuous splashing of water or other similar rust formation fluids may caserust attach on the robots unpainted areas, joints, or other unprotected sur-faces. Under these circumstances it is recommended to add rust inhibitor tothe fluid or take other measures to prevent potential rust formation on thementioned.The entire robot is IP67 compliant according to IEC 60529 - frombase to wrist, which means that the electrical compartments are sealedagainst liquid and solid contaminants. Among other things all sensitive partsare better protected than the standard offer.Selected Foundry Plus/Foundry Plus 2 features:

Improved sealing to prevent penetration into cavities to secure IP67 Additional protection of cabling and electronics Special covers protecting cavities Well-proven connectors Rust preventives on screws, washers and unpainted/machined surfaces Extended service and maintenance program

The Foundry Plus 2 robot can be cleanedwith appropriate washing equipment.




2.2 Manipulator

Continued

DescriptionOption

Foundry Prime 2287-6 i

The robot version Foundry Prime is designed for water jet cleaning of castsandmachined parts, washing applications and similar very harsh, but provenrobotic application environments. Applicability in other applications cannotbe guaranteed without prior testing, previous experience or professionaljudgment by ABB. Please contact ABB Robotics Sales organization if insmallest doubt regarding specific application feasibility. Foundry Prime robotsmust follow detailed operational and maintenance requirements for the ap-plication in question, please refer to product specification and productmanual for details.The manipulator can withstand surrounding solvent based detergents whichmust be approved by ABB. In addition, the manipulator can withstand indirectspray from jet pressure (max. 600 bar) and 100% humidity (gaseous mixtureonly). The manipulator can work in an environment with a cleaning bathtemperature < 60o C, typically used in a washing application with moderaterobot speed. Surrounding temperate cannot be higher than specified for theoption. If fluids that may cause rust formation, for example water, are continu-ous splashing the robot or are used in the vicinity of the robot it is stronglyrecommended to add rust inhibitor to the fluid or take other measures toprevent potential rust formation on the robots unpainted areas, joints, orother unprotected, surfaces. The robot is protected by well-proven sealingsfor gears and bearings, pressurizedmotors and electronic compartment, anddetergent resistant painting system in three layers (two layer epoxy paintunder a protective layer of clear coat). Non painted surfaces has rust prevent-ive coating (Mercasol), and motors (IRB 4400) are sealed with a sealingcompound.As the robot is designed for very harsh environments, an extendedservice and maintenance program is required. Special care must be takenwhen replacing parts or performing othermaintenance and service that breaksthe paint surface as the paint surface act as a protective barrier. For detailedinformation of the maintenance program, see chapter Maintenance in theProduct Manual. It is highly recommended to sign a Service Agreement withABB due to difficult and severe environmental conditions. The Foundry Primerobot can be cleaned with appropriate washing equipment according toproduct manual. Appropriate cleaning and maintenance are required tomaintain the Foundry Prime protection, for example can the rust preventivebe washed off with wrong cleaning method.General detergent requirements

Washing detergent with max pH

DescriptionOption

209-2 ABB White standard 209 RAL code 213-1 Safety lamp 87-1 Cooling fan for axis 1 motor 88-1 Cooling fan for axis 2 motor 429-1 Underwriters Laboratories 438-2 Standard + 12 Months 438-4 Standard + 18 Months 438-5 Standard + 24 Months 438-6 Standard + 6 Months

i Only available for IRB 4600-60/2.05

Mounting position

DescriptionOption

Invertedmounting of themanipulator Not together with option 603-1, AbsAcc.224-2

Note

Manipulators delivered for floor mounting must have the option added beforechanging mounting position to inverted.

Media & CommunicationAir supply and signals for extra equipment upper arm, see 1.9 Customerconnections.

DescriptionTypeOption

Includes customer power CP and customer signalsCS + air.

Parallel and pair com-munication

803-1

Includes CP, CS and PROFINET or Ethernet/IP + air.Ethernet, parallel andair communication

803-2

Includes CP, CS and Devicenet + airDeviceNet, parallel andair communication

803-3

Includes CP, CS and PROFIBUS + airPROFIBUS803-4

Connector kitThe kit consists of connectors, pins and sockets

DescriptionOption

For the connectors on the upper arm.431-1

For the connectors on the foot if connection to manipulator.239-1

Safety lamp

DescriptionOption

Safety lamp safety lamp with an orange fixed light can be mounted on themanipulator.The lamp is active in MOTORS ON mode.The safety lamp is re-quired on a UL/UR approved robot.

213-1




2.2 Manipulator

Continued

xx0800000427

Cooling fans for axis 1 and 2 motorTo be used to avoid overheating of motors and gears in application with intensivemotion (high average speed and/or high average torque and/or short wait time) ofaxis 1 and axis 2. IP54 valid for cooling fan.

DescriptionOption

Cooling fan for axis 1 motor.87-1

Cooling fan for axis 2 motor.88-1

Resolver connection, axis 7A connector for resolver signals for axis 7 located on the base

RemarkDescriptionOption

Needed for Connection box (BRB), option 1018-1 to-3, on Specification Form for Motor Units. Used to-gether with first additional drive option 770-4.

On base864-1

Electronic Position Switches (EPS)The mechanical position switches indicating the position of the three main axesare replaced with electronic position switches for up to 7 axes, for increasedflexibility and robustness. For more detailed information, see Productspecification - Controller IRC5with FlexPendant andApplicationmanual - ElectronicPosition Switches.

Working range limit-Axis 1The working range of axis 1 can be limited between 129o to 16.5o in steps of22.5o

DescriptionOption

Two stops for restricting the working range.The stops can be mounted ac-cording to example in.

28-1 Axis 1




2.2 Manipulator

Continued

AB

C

xx0800000410

DescriptionPos

Movable mechanical stop, limited to - 129oA

Movable mechanical stop, limited to + 16.5oB

Movable mechanical stop, limited to - 16.5oC

Warranty


Standard warranty is 18months fromCustomer DeliveryDate or latest 24 months after Factory Shipment Date,whichever occurs first. Warranty terms and conditionsapply.

Standard warranty438-1

Standard warranty extended with 12 months from enddate of the standard warranty. Warranty terms and con-ditions apply. Contact Customer Service in case of otherrequirements.

Standard warranty + 12months

438-2

Standard sarranty extended with 18 months from enddate of the standard warranty. Warranty terms and con-ditions apply. Contact Customer Service in case of otherrequirements.


438-4




2.2 Manipulator

Continued


Standard warranty extended with 24 months from enddate of the standard warranty. Warranty terms and con-ditions apply. Contact Customer Service in case of otherrequirements.


438-5

Standard warranty extended with 6 months from enddate of the standard warranty. Warranty terms and con-ditions apply.


438-6

Standard warranty extended with 30 months from enddate of the standard warranty. Warranty terms and con-ditions apply.


438-7

Maximum 6 months postponed start of standard war-ranty, starting from factory shipment date. Note that noclaims will be accepted for warranties that occurred be-fore the end of stock warranty. Standard warranty com-mences automatically after 6 months from FactoryShipment Date or from activation date of standard war-ranty in WebConfig.

Note

Special conditions are applicable, seeRoboticsWarrantyDirectives.

Stock warranty438-8



2.2 Manipulator

Continued

2.3 Floor cables

Manipulator cable length

LengthsOption

7 m210-2

15 m210-3

22 m210-4

30 m210-5

Application interface Connection to

DescriptionNameOption

The signals are connected to 12-pole screw termin-als, Phoenix MSTB 2.5/12-ST-5.08, to the ControlModule.

Cabinet16-1

Connection of Parallel/CAN DeviceNet communicationFollowing information specifies the cable length for Parallel/CANDeviceNet/Ether-net + PROFIBUS floor cables for connections between cabinetsand manipulator.

LengthsOption

7m94-1/90-2/859-1/92-2

15m94-2/90-3/859-2/92-3

22m90-4/859-3/92-4

30m94-4/90-5/859-4/92-5



2.3 Floor cables

2.4 Process

Process module


See Product specification - Controller IRC5 withFlexPendant, list of variants

Empty cabinet small768-1


Empty cabinet large768-2

WeldGuide III


Only together with ArsitoMig 4000i/5000i, MigRob andTPS power sources. Digital I/O or AD Combi I/O isneeded for WeldGuide functions. Requires optionWeldGuide MultiPass [815-2].

Basic958-1

Only together with ArsitoMig 4000i/5000i, MigRob andTPS power sources. Digital I/O or AD Combi I/O isneeded for WeldGuide functions. Requires optionWeldGuide MultiPass [815-2].

Advanced958-2

Installation kit



Installation kit715-1

Torch service


ABB Torch Service CenterABB TSC1037-1

ABB Torch CleanerABB TC961037-2

BullsEye stand aloneBullsEye1037-5

Torch service options


Extension pedestal for TSC/TC/BullsEyeExtension pedestal1038-1



2.4 Process

2.5 Documentation

DVD User DocumentationThe user documentation describe themanipulator system in detail, including serviceand safety instructions. All documents are available on the documentation DVD,3HAC032875-001.


See Product specification - Robot user documentationDocumentation onDVD808-1



2.5 Documentation

3 Accessories3.1 Introduction to accessories

GeneralThere is a range of tools and equipment available, especially designed for themanipulator.

Basic software and software options for robot and PCFor more information, see Product specification - Controller IRC5 with FlexPendantand Product specification - Controller software IRC5.

Robot peripherals Track Motion

Motor Units

Positioners


3 Accessories

3.1 Introduction to accessories

IndexAaccessories, 67

CCalibration Pendulum, 25

Ddocumentation, 65

EElectronic Position Switches, 60EPS, 60

Ffine calibration, 25

Iinstructions, 65

Mmanuals, 65

Ooptions, 55

Pprotection standards, 18

Ssafety standards, 18service instructions, 65standards

ANSI, 19CAN, 19EN, 18EN IEC, 18EN ISO, 18protection, 18safety, 18

standard warranty, 61stock warranty, 61

Uuser documentation, 65

Vvariants, 55

Wwarranty, 61


Index

Contact us

ABB ABDiscrete Automation and MotionRoboticsS-721 68 VSTERS, 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

3HAC03

2885

-001

,Rev

M,e

n

Cover PageTable of contents1 Description1.1 Structure1.1.1 Introduction to Structure1.1.2 Different robot versions

1.2 Standards1.2.1 Applicable safety standards

1.3 Installation1.3.1 Introduction to Installation1.3.2 Operating requirements1.3.3 Mounting the manipulator

1.4 Calibration and references1.4.1 Fine calibration1.4.2 Absolute Accuracy calibration

1.5 Robot load and load diagrams1.5.1 Introduction to Robot load and load diagrams1.5.2 Load diagrams1.5.3 Maximum load and moment of inertia for full and limited axis 5 (centerlinedown) movement1.5.4 Wrist torque

1.6 Mounting equipment1.6.1 Information about mounting equipment

1.7 Maintenance and Troubleshooting1.7.1 Introduction to Maintenance and Troubleshooting

1.8 Robot Motion1.8.1 Introduction to Robot Motion1.8.2 Performance according to ISO 92831.8.3 Velocity1.8.4 Stopping distance/time

1.9 Cooling fan for axis 1-2 motor1.10 Customer connections1.10.1 Introduction to Customer connections

2 Specification of variants and options2.1 Introduction to variants and options2.2 Manipulator2.3 Floor cables2.4 Process2.5 Documentation

3 Accessories3.1 Introduction to accessories

Index

abb product specification irb4600

Documents

robot load

load diagrams

maximum load

fine calibration

different robot versions

absolute accuracy calibration

consequential damages

damages topersons