ABB IRB 4600 Foundry Prime Product Manual

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IRB 4600 Foundry Prime

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Summary of Contents for ABB IRB 4600 Foundry Prime

Page 1 ROBOTICS Product manual IRB 4600 Foundry Prime...
Page 2 Trace back information: Workspace R18-2 version a18 Checked in 2018-11-20 Skribenta version 5.3.012...
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Mechanically restricting the working range of axis 1 ........Installing options ....................2.6.1 Installing an expansion container ............... Robot in hot environments .................. 2.7.1 Start of robot in hot environments .............. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 6 Customer connection on robot ..............2.9.3 Customer connections on upper arm ............2.10 Additional installation (Foundry Prime) ..............2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application ...... 2.10.2 Commissioning (Foundry Prime) ..............Maintenance Introduction ...................... Introduction for Foundry Prime robots ..............
Page 7 Weight specifications ..................Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare part lists Spare part lists and illustrations ................Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 9: Overview Of This Manual
ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 4600 Foundry Prime. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 This manual contains all safety instructions from the product manuals for the manipulators and the controllers. Revisions Revision Description First edition Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 11: Product Manual - Irb
Added information regarding tightening of protective calibration plugs after calibration. Risk of damage on sealing washer if tightened too hard. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 12 Changed the method for replacing the axis-1 gearbox and the base. Published in release R18.2. The following updates are made in this revision: • Updated references. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 13: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 14 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 15: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 16: Important Information About Robots With Protection Type Foundry Prime
For more information, see Pressurized components on page Cleaning Special procedures are needed when cleaning the Foundry Prime robot. See section Cleaning the IRB 4600 Foundry Prime on page 191. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M...
Page 17: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
Page 18 Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.
Page 19: Protective Stop And Emergency Stop
1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 20: Safety Actions
1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 21: Emergency Release Of The Robot Axes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 22: Make Sure That The Main Power Has Been Switched Off
Note Switch off all main power switches in a MultiMove system. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 23: Safety Risks
Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 24 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.
Page 25: Moving Robots Are Potentially Lethal
Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 26: First Test Run May Cause Injury Or Damage
When programming the movements of the robot, always identify potential collision risks before the first test run. Mechanical stops will not always stop the movements of the robot completely. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 28: Enabling Device And Hold-To-Run Functionality
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 29: Risks Associated With Live Electric Parts
The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 30 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 31: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 32: Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 33: Safety Risks Related To Pneumatic/Hydraulic Systems
Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 34: Safety Risks With Pressure Relief Valve
If too much air pressure has been built up, there is a risk of personal injury and mechanical damage. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 35: Brake Testing
3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 36: Safety Risks During Handling Of Batteries
Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 37: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 38 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 39: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 40 Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 41: Safety Symbols On Product Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 42 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 43 The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 44 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 45 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 46 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 47: Installation And Commissioning
Safety on page 17 before performing any installation work. Note If the IRB 4600 Foundry Prime is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: •...
Page 48: Installation And Operational Requirements For Foundry Prime Robots
Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 49 >200 L/min Pressurizing equipment ABB recommends a safety valve (if not included) set at 0.4 bar, pressure sensor set at 0.2-0.3 bar or regulator set for maximum 0.3 bar to be attached on the pressure side of the air system.
Page 50 The sealing joints between the moving parts on the wrist must not be exposed to high pressure water. Rebounding high pressure water jet must be avoided. ABB recommends using a tool design with integrated covers that protect the wrist from direct or indirect high pressure water jet.
Page 51 The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independent of Motors On/Off mode, start-up and shut down periods. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 52: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 53 The robot installation is restricted to the mounting options given in following load table(s). Floor mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ±3950 N ±7800 N Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 54 This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 55 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Foundry Prime IP 67 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 56: Surface Inspection Before Start-Up - Foundry Prime
Protect attachment bolts and washers at the base Protect the attachment bolts and washers (M24x100) at the base from physical obstructions and splashes with appropriate shield. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 57: Working Range And Type Of Motion
Pos. E Pos. F IRB 4600 - 60/2.05 2371 mm 1260 mm 1028 mm 593 mm 1701 mm 2051 mm Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 58 Pos. E Pos. F IRB 4600 - 60/2.05 2371 mm 1260 mm 1028 mm 593 mm 1701 mm 2051 mm Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 59 Axis 3 Arm motion +75° / -180° Axis 4 Wrist motion ±400° Axis 5 Bend motion +120° / -125° Axis 6 Turn motion ±400° Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 60: Risk Of Tipping/Stability
The position of the calibration mark (A) in the figure is approximate and is used as aiming aid. 0° xx0800000263 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 61: On-Site Installation
Roundsling put folded in U-shape through the lifting lug Roundsling put folded in U-shape around gearbox axis 3 Lifting lug Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 62 Lifting instructions Use this procedure to lift the robot in a safe way. Action Note CAUTION The IRB 4600 Foundry Prime robot weighs 440 kg. All lifting accessories used must be sized ac- cordingly! CAUTION Attempting to lift the robot in any other posi-...
Page 63 A: Area where the connection box can be damaged while lifting. Lift the robot with an overhead crane. Lifting capacity: • Required equipment on page 61 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 64: Lifting And Turning A Suspended Mounted Robot
Special tools on page 394. Any additional equipment required is specified in the instruction for the lifting accessory. Contact ABB for more information. Illustration xx1500002116 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 65: Setting The System Parameters For A Suspended Or Tilted Robot
The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 66 B is the mounting angle in radians. Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 67 Examples of mounting angles tilted around the Y axis (Gravity Beta) xx1700000267 Floor mounted Tilted mounting, mounting angle 15°. Suspended mounting, mounting angle 180°. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 68 The system parameters are described in Technical reference manual - System parameters. The system parameters are redefined in the Configuration Editor, in RobotStudio or on the FlexPendant. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 69: Manually Releasing The Brakes
The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 70 See the previous figure. The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 71 If they are mixed up, damage can be caused to the intergrated quenching circuits. WARNING Incorrect connections can cause all brakes to be released simultaneously! xx1400001984 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 72: Orienting And Securing The Robot
The illustration shows the hole configuration used when securing the robot. xx0800000271 Hole for guide bushing Rear bolt holes Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 73 M16 x 70/80 (installation on foundation or base plate, us- ing guide bushings) Quality 8.8 Washers 17 x 30 x 3 6 pcs Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 74 • Hole configuration, base on page 72 CAUTION The IRB 4600 Foundry Prime robot weighs 440 kg. All lifting accessories used must be sized accordingly! CAUTION When the robot is put down after being lifted or transported, there is a risk of it tipping, if not properly secured.
Page 75 Screw joints must be able to withstand the stress loads defined in section Loads on foundation, robot on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 76: Fitting Equipment On Robot
All equipment and cables used on the robot, must be designed and fitted not to damage the robot and/or its parts. Note Never drill a hole in the robot without first consulting ABB! Fitting equipment on robot - Load areas The shaded area indicates the permitted positions (center of gravity) for any extra equipment fitted in the holes intended for this purpose.
Page 77 The illustrations show the fitting holes available for fitting extra equipment on the base and frame of the robot. xx0800000276 Attachment holes on base Center axis 2 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 78 216 (2x M8 16) (3x M8 3x M8 2x M8 16 xx0800000280 Center axis 4 Center axis 3 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 79 Remove these to fit extra equipment. Seal with Mercasol. Note If extra equipment is removed, cover up equipment holes with coated set screws. Seal with Mercasol. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 80 Screws not to be removed! Do not use these holes for fitting equipment on the wrist! Screw hole intended for swivel fitting. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 81 17 1 0,3 C D E R 50 9 min. xx1600000626 Note Use attachment screws M10, quality 12.9 and 15 mm used thread length. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 82: Surface Inspection Before Start-Up - Foundry Prime
Protect attachment bolts and washers at the base Protect the attachment bolts and washers (M24x100) at the base from physical obstructions and splashes with appropriate shield. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 83: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 84: Installation Of Signal Lamp (Option)
2.4.9 Installation of signal lamp (option) 2.4.9 Installation of signal lamp (option) Signal lamp See the assembly instruction delivered with the signal lamp. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 85: Restricting The Working Range
Remove the mechancial stop bracket if the robots full working range is from a mechanical stop to another mechanical stop. Otherwise the mechanical stop pin will be worn out. xx1500000253 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 86: Mechanically Restricting The Working Range Of Axis 1
These procedures include references to the may be required. See refer- tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 87 Action Note Determine the position of the stop lugs. See the figure Additional stops on page 87 for guidance. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 88 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 89: Installing Options
O-ring D220x5 Attachment screw M5x20, quality 8.8-A2F and washer (2+2 pcs) O-ring D1=9.5 D2=1.6 Oil plug (to be removed) Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 91 Turn the robot to suspended position. Inspect the oil level. See procedure for suspended robot, specting oil level, axis 1 gearbox on page 113. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 92: Robot In Hot Environments
Let the overpressure leave the gearbox. Refit the oil plug. Continue releasing the overpressure on all gearboxes. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 93: Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 94: Electrical Connections
3HAC026787-001 Robot cable, power: 15 m 3HAC026787-002 Robot cable, power: 22 m 3HAC026787-003 Robot cable, power: 30 m 3HAC026787-004 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 95 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1600001004 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 96: Customer Connection On Robot
The customer connections are located on the robot as shown in the figure. Customer connection. xx1700002241 Air M16x1.5 (24° cone sealing) R2.CP R2.CS R2.ETHERNET Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 97 Hinged frame, hood • Multicontact-module, female • Hose coupling Connector set R1.CP/CS 3HAC033181-001 on base • M12 connector, male Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 98 Content • Pins for cable area 0.21 - 0.93 R2.CP/R2.CS R2.CP/R2.CS 3HAC025396-001 mm² • Bottle shaped shrinking hose • Angle shaped shrinking hose Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 99: Customer Connections On Upper Arm
XP6.2 R2.CP.B R1.CP/CS.d6 XP6.3 R2.CP.C R1.CP/CS.d3 XP6.4 R2.CP.D R1.CP/CS.d4 XP6.1 R2.CP.E R1.CP/CS.d1 XP6.2 R2.CP.F R1.CP/CS.d6 R2.CP.G (Earth) R2.CP.H R1.CP/CS.d7 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 100 R2.CS.S R1.CP/CS.b16 XP5.3.3 R2.CS.T R1.CP/CS.b18 XP5.3.4 R2.CS.U R1.CP/CS.b19 XP5.3.5 R2.CS.V R1.CP/CS.b20 XP5.3.6 R2.CS.W R1.CP/CS.b21 XP5.2.9 R2.CS.X R1.CP/CS.b22 XP5.2.10 R2.CS.Y R1.CP/CS.b23 XP5.2.11 R2.CS.Z R1.CP/CS.b24 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 101: Additional Installation (Foundry Prime)
2 Installation and commissioning 2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application 2.10 Additional installation (Foundry Prime) 2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application General Robots delivered with the Foundry Prime protection are specially designed to work in water jet cleaning cells with 100% humidity and alkaline detergent.
Page 102 2 Installation and commissioning 2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application Continued WARNING If the air pressure exceeds the specified, it could result in a brake failure in the motors and cause the robot arms to fall down, leding to personal injure or physical damage.
Page 103 2 Installation and commissioning 2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application Continued Protecting the wrist joints The sealings between the moving parts on the wrist must not be exposed to direct high-pressure water. We recommend that the gripper include a shield that prevents direct water flush on the sealing surfaces of the wrist.
Page 104 2 Installation and commissioning 2.10.1 Installation of IRB 4600 Foundry Prime in a water jet application Continued Action Note/Illustration Before running the robot in a water jet Inspection of air hoses (Foundry Prime) cleaning cell: on page 148 • perform a inspection of the pressure in motors and SMB cavity.
Page 106 This page is intentionally left blank...
Page 107: Maintenance
Safety on page 17 before performing any service work. Note If the IRB 4600 Foundry Prime is connected to power, always make sure that the IRB 4600 Foundry Prime is connected to protective earth before starting any maintenance work. For more information see: •...
Page 108: Introduction For Foundry Prime Robots
To eliminate these risks appropriate equipment and procedures are required when installing, cleaning, maintaining, and repairing ABB Foundry Prime robots. An extended maintenance program including service activities and schedule is required.
Page 109: Maintenance Schedule
Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 4600 Foundry Prime: • Calendar time: specified in months regardless of whether the system is running or not.
Page 110: Maintenance Schedule
Every: • 12 months Inspection Dampers Every: • 12 months Inspection Mechanical stop, axis 1 Every: • 12 months Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 111 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 112: Expected Component Life
SIS (See the Operating manual - Service Infomation System) In applications such as Foundry or Washing the robot can be exposed to chemicals, high temperature or humidity which can have an effect on the lifetime of gearboxes. Contact the local ABB Robotics Service team for more information.
Page 113: Inspection Activities
Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Foundry Prime touch up kit 3HAC035355-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 114 Current design: xx1000000669 Oil plug draining, on gearbox Oil plug filling, on surface for motor flange Surface for motor flange Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 116 Inspecting the gearbox oil level in a suspended robot Location of oil plugs (suspended) Old design: xx1200000883 Oil plug, filling Oil plug, draining Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 117 Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 118 Foundry Prime paint coat of the robot. See Cut the paint or surface on the robot before replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 119: Inspecting The Oil Level, Axis 2 Gearbox
See references to these procedures in the tools required. step-by-step instructions below. Additional equipment - Foundry Prime Equipment Art. no. Note Rust preventive 3HAC034903-001 Mercasol Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 120 Measure the oil level at the oil plug hole. Required oil level: • 42 mm ± 5 mm below the lower edge of the oil plug hole. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 121 Foundry Prime paint coat of the robot. See Cut the paint or surface on the robot before replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 122: Inspecting The Oil Level, Axis 3 Gearbox
Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Foundry Prime touch up kit 3HAC035355-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 123 171 Refit the oil plug. Tightening torque: • in armhouse: 10 Nm • in gearbox: 3 Nm Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 124 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 125: Inspecting The Oil Level, Axis 4 Gearbox
Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Foundry Prime touch up kit 3HAC035355-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 126 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 127: Inspecting Oil Level, Gearbox Axes 5 - 6
Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Foundry Prime touch up kit 3HAC035355-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 128 Changing oil, axes-5 and -6 gear- boxes on page 181 Refit the oil plugs. Tightening torque: • 10 Nm Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 129 Cut the paint or surface on the robot be- fore replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 130 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 131: Inspecting The Cable Harness
See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram See chapter Circuit diagram on page 401. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 132 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 133: Inspecting Information Labels
Label - Calibration Label - Suspended robot Required equipment Equipment Spare part number Note Labels Spare part lists on page 399. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 134 Check all labels. See the figure in Location of information labels on page 133. Replace any missing or damaged labels. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 135: Inspecting The Mechanical Stop Pin, Axis 1
Additional equipment - Foundry Prime Equipment Article number Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 137 Check that the mechanical stop pin can move freely in both directions and the bracket works as it is supposed to. xx1000000222 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 138 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 139: Inspecting Additional Mechanical Stops
For spare part number see Spare part lists on page 399. Standard toolkit Content is defined in section Standard tools on page 393. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 140 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 141: Inspecting Dampers
Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Foundry Prime touch up kit 3HAC035355-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 142 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 143: Inspecting The Leak Proof O-Ring And Pressure Relief Valves
3HAC035355-001 Leak spray Required consumables Consumable Article number Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 144 Make sure not to lose the small o-ring. xx1700001174 • Screw • Cover • O-ring 6.1 mm • O-ring 41 mm Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 145 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 146: Inspecting Signal Lamp (Option)
Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Foundry Prime touch up kit 3HAC035355-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 147 Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 148: Inspection Of Air Hoses (Foundry Prime)
If the answer is NO: The system is OK. Remove the leak testing equipment. Pressurize by opening the cut off valve. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 149 Note Spray suspected leak areas with leak detec- tion spray. Note Bubbles indicate a leak. When the leak is localized: correct the leak. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 150: Inspection Of Surface Treatment (Foundry Prime)
Use this procedure to inspect the surface treatment on Foundry Prime robots. Action Information Inspect all painted surfaces for damages. Repair damages as described in the instruc- tion included in the spare part kit. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 151: Replacement Activities
Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
Page 152 Nipple for quick connect fitting, with o-ring Used on the axis-2 gearbox. Expansion container, gearbox axis 1 Used when the robot is fitted in a suspended position. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 153: Changing The Oil, Axis 1 Gearbox On Floor Mounted Robots
The oil plugs are shown in the figure. Old design: xx0800000304 Oil plug, filling and venting Oil plug, draining Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 154 Content is defined in section Standard tools on page 393. Additional equipment - Foundry Prime Equipment Art. no. Note Rust preventive 3HAC034903-001 Mercasol Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 155 Open the oil plug carefully in order to let out the ex- cess pressure. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 156 Suck out the oil with the oil dispenser. Note There will be some oil left in the gear after draining. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 157 If the robots paint coat is damaged during Inspection and repair of surface the procedure, paint touchup is needed. treatment on page 150 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 158 Open the oil plug, filling. Different position due to design differ- ences: xx1800001137 xx1800001139 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 159 Also repair possible damages of the special Foundry Prime paint coat of the robot. See the paint or surface on the robot before repla- cing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 160: Changing The Oil, Axis-1 Gearbox On Suspended Robots
Other design than Type C: xx1200000883 Oil plug, venting Oil plug, draining and filling Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 161 One example of oil dispenser can be found in section: • Type of lubrication in gearboxes on page 151 Oil change equipment Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 162 Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 163 The same amount shall later be refilled. after draining. Measure the volume of the drained oil in the vessel. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 165 When the robot is fitted in a suspended mounted position, an expansion container for oil must be fitted on gearbox axis 1. xx0900000129 Expansion container Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 166 If a floor mounted robot shall be fitted in a suspended mounted position, an expansion container must be installed. See Installing an expansion container on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 167: Changing The Oil, Axis-2 Gearbox
Location of oil plugs on page 167. Standard toolkit Content is defined in section Standard tools on page 393. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 168 Location of oil plugs on page 167 fitting in the hole for draining • remove the quick connect fitting. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 169 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 170 Foundry Prime paint coat of the robot. See Cut the paint or surface on the robot before replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 171: Changing The Oil, Axis-3 Gearbox
One example of oil dispenser can be found in section: • Type of lubrication in gearboxes on page 151 Funnel xx1200000862 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 172 Note Move the robot to an upright position as shown in the figure. xx0800000327 • A: Oil collecting vessel Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 173 See the figure in: where the oil plug, gearbox is pointing at the • Location of oil plugs on page 171 floor. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 174 See section De- commissioning for more information. Note There will be some oil left in the gearbox after draining! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 175 Open the oil plug, armhouse. See the figure in: • Location of oil plugs on page 171 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 176 Also repair possible damages of the special Foundry Prime paint coat of the robot. See the paint or surface on the robot before repla- cing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 177: Changing The Oil, Axis-4 Gearbox
A suitable hose would be a hose normally used for compressed air. Length: minimum 300 mm. Diameter: 5 mm. Funnel xx1200000862 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 178 Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 179 Use this procedure to fill oil in the gearbox. Action Note Move the upper arm to the position shown in the figure. xx0800000330 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 180 Foundry Prime paint coat of the robot. See Cut the paint or surface on the robot before replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 181: Changing Oil, Axes-5 And -6 Gearboxes
393. Additional equipment - Foundry Prime Equipment Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 182 Location of oil plugs on page 181 This is done for the ventilation of the gear- box and to fascilitate draining. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 183 Location of oil plugs on page 181 Open oil plug, tilthouse. See the figure in: • Location of oil plugs on page 181 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 184 Foundry Prime paint coat of the robot. See Cut the paint or surface on the robot before replacing parts on page 201. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 185: Replacing Smb Battery
See Operating manual - IRC5 with FlexPendant for instructions. WARNING See instructions for batteries, Safety risks during handling of batteries on page Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 186 SMB battery (2-pole battery contact) Battery cover Attachment screws SMB battery cable How to arrange the battery cable Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 187 Do not replace the battery contact! Equipment Note SMB battery pack Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved equivalent. Spare part lists on page 399. Standard toolkit Content is defined in section Standard tools on page 393.
Page 188 186. How to dispose of the used SMB battery, see chapter Decommissioning on page 381. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 189 These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 190: Analysis Activities
Normal replacement interval is required for the gearbox. 3000 6000 9000 12000 15000 xx0600003156 • A: Water content in gearbox oil • B: Months or hours in operation Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 191: Cleaning Activities
Turn off all electrical power supplies to the manipulator before entering its work space. General To secure high uptime it is important that the IRB 4600 Foundry Prime is cleaned regularly. The frequency of cleaning depends on the environment in which the product works.
Page 192 3 Maintenance 3.7.1 Cleaning the IRB 4600 Foundry Prime Continued • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. • Do not remove any covers or other protective devices before cleaning the robot.
Page 193 • No other additive than water is guaranteed without prior testing or agreement with ABB. Other additives than water may have a harmful effect on the life of the robot and its components. • Recommendations given by the detergent manufacturer for the specific detergent in question must be followed.
Page 194 This page is intentionally left blank...
Page 195: Repair
Safety on page 17 before commencing any service work. Note If the IRB 4600 Foundry Prime is connected to power, always make sure that the IRB 4600 Foundry Prime is connected to earth before starting any repair work. For more information see: •...
Page 196: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 197: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 198 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 199: Mounting Instructions For Seals
Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 200 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 201: Cut The Paint Or Surface On The Robot Before Replacing Parts
Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 202 Always read the instruction in the product data sheet in the paint repair kit for Foundry Prime. Apply Mercasol on all screw heads and set screws after tightening. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 203: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 204: Complete Robot
• Brake release unit Removing the brake release board on page 253 • Motors Removing motors on page 305 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 205 Cable harness, base and frame. xx0900000009 Cover base Bracket Cable harness Axis-1 motor cable Axis-2 motor cable Axis-2 motor Axis-1 motor Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 206 These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 207 Use this procedure to remove the cable harness in the base. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 208 201. Remove the cover base. xx0800000456 A Base B Cover base C Attachment screws Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 209 B R1.SMB C Bracket D Air connector Unscrew the nut for the air connection on the inside of the bracket. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 210 How to remove the SMB unit is described screws. in section: • Removing the SMB unit on page 247 Leave the screws in the base. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 211 • A: Screen connection (4 pcs) Disconnect the earth cables. xx0900000015 Parts: • A: Earth • B: Distance screws Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 212 How to remove the motor cables is de- and axis-2 motors. scribed in section: • Removing motors on page 305 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 213 • Removing cable harness in lower arm and armhouse on page 214 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 214 Cut the paint or surface on the robot before replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 215 Remove the bracket on the armhouse. xx0800000335 Parts: • A: Tubular shaft unit • B: Attachment screws • C: Bracket, armhouse Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 217: Refitting The Complete Cable Harness
• Brake release unit Refitting the brake release board on page 255 • Motors Refitting motors on page 314 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 218 Cable harness, base and frame. xx0900000009 Cover base Bracket Cable harness Axis-1 motor cable Axis-2 motor cable Axis-2 motor Axis-1 motor Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 219 Cable grease Shell Alvania WR2 Additional equipment - Foundry Prime Equipment Art. no. Note Rust preventive 3HAC034903-001 Mercasol Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 220 Two alternative methods to insert the cable package in frame and base are presented below. Chose one of the methods. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 221 Note Use caution when performing this procedure in order not to damage cables or other components! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 222 Note Use caution when performing this procedure in order not to damage cables or other components! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 223 Connect the axis-1 and axis-2 motor cables. How to refit the motor cables is described in section: • Refitting motors on page 314 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 224 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 225 Secure the bracket with its attach- ment screws. xx0900000018 Parts: • A: Base • B: Attachment screws (2 pcs) • C: Bracket Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 226 When refitting connectors on the bracket, put it at a 90° angle. xx0900000013 Parts: • A: Bracket • B: Base Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 227 E: R1.CP/CS • F: R1.MP • G: Air hose • H: Position of R1.ETHERNET (if used) • J: R1.SMB Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 228 Refit the air hose connector on the bracket. Note Check that there is no leakage from the air hose. Reconnect the battery cable. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 229 • Refitting the cable harness in the lower arm and armhouse on page 230 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 230 Location of the cable harness on page 218 (Cable harness, lower arm) Push the cable harness carefully into the armhouse. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 231 Calibrating with Axis Calibration method on page 364. General calibration information is included in section Calibration on page 353. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 232 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 233: Replacement Of Air Nipples And Hoses (Foundry Prime)
These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Loctite 577 12691907-1 Rust preventive 3HAC026621-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 234 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 235 Replacing air hoses and nipples The illustration show the routing of the pressure hoses on a IRB 4600 Foundry Prime robot. xx1100000049 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 236 23 Remove hose, and remove the straight fitting from the manipulator base. xx1500002400 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 237 1 and 2. Use standard tools. xx1100000053 Remove the hoses from the elbow fit- tings. No tools needed. xx1100000054 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 238 No tools needed. xx1100000056 Remove the straight fittings on the cover at the frame. Use standard tools. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 239 Remove the Pneumatic hose - Foundry Prime 2500 mm from the upper elbow- fitting. xx1100000059 Remove the upper elbow fitting. xx1100000060 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 240 Remove all hose clamps (A) from the lower arm. xx1100000057 Remove the Pneumatic hose - Foundry Prime 2500 mm from the upper arm. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 241 Refit the straight fitting on the manip- ulator base. Apply Loctite 577 on the thread. Use standard tools. xx1500002401 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 242 Refit the upper elbow fitting. Apply Loctite 577 on the thread. Use standard tools. xx1100000061 Refit the upper hose in the elbow- fitting. xx1100000062 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 243 Refit the elbow fittings on the mo- tors. Apply Loctite 577 on the thread. Use standard tools. xx1100000068 Refit the hose on the elbow fitting. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 244 Apply Loctite 577 on the thread. Use standard tools. Refit the hoses on the straight fit- tings on the cover at the frame. xx1100000070 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 245: Replacing Smb Unit
Do not replace the battery contact! Equipment Note Standard toolkit Content is defined in section Standard tools on page 393. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 246 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 247 B Base cover C Cable straps, securing the battery cable (2 pcs) Cut the cable straps securing the battery cable. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 248 SMB unit just enough to be able to re- • Location of SMB unit on page 245 move the SMB unit. Remove the SMB unit. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 249 See the figure in: screws. • Location of SMB unit on page 245 Secure the SMB unit with its attachment screws. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 250 Foundry Prime paint coat of the robot. See Cut the paint or surface on the robot before replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 251 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 252: Replacing The Brake Release Board
The connectors X8, X9 and X10 are placed on the push-button board as shown in the figure below. xx1700000978 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 253 The unit is sensitive to ESD. Before handling the unit read the safety information in sec- tion The unit is sensitive to ESD on page 31 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 254 Disconnect connectors X8, X9 and X10 from the brake release board. xx1700000978 Remove the nuts securing the brake release board. Remove the brake release board. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 255 Eliminate all risks of contact between screened cables and the brake release board. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 256 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 257: Replacing The Base
Lifting capacity: 1,000 kg. Support legs 3HAC15535-1 3 pcs Guide pin, M8x150 3HAC15520-2 Always use guide pins in pairs. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 258 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 259 • Removing cable harness in lower keep it undamaged during the remaining arm and armhouse on page 214 work. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 260 A Roundsling 1.5 m B Roundsling 2 m C Roundsling 2 m CAUTION The IRB 4600 Foundry Prime robot weighs 440 kg. All lifting accessories used must be sized accordingly! Remove the bolts that secure the robot to the foundation.
Page 261 Fit two guide pins in opposite holes in the Guide pin, M8x150: 3HAC15520-2 axis-1 gearbox. Always use guide pins in pairs. xx1800000883 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 262 Remove the support legs attachments screws and remove the base from the sup- port legs. xx1800000885 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 263 Remove residues of old Loctite and other contaminations from surfaces before apply- ing new Loctite 574. Use Loctite 7063 (or similar) for cleaning. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 264 Fit two guide pins in opposite holes in the Guide pin, M8x150: 3HAC15520-2 axis-1 gearbox. Always use guide pins in pairs. xx1800000932 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 265 Remove the screws that secure the support legs to the foundation. DANGER Stretch the roundslings to make sure that the robot weight is secured. xx1800000875 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 266 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 267: Upper Arm
For spare parts no. see Spare parts - Upper arm (2.05/2.50/2.55) in Product manual, spare parts - IRB 2600. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 268 Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Foundry Prime touch up kit 3HAC035355-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 269 Run the robot to the position shown in the figure. The robot must be floor mounted and the upper arm must be horizontally positioned. xx0800000336 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 270 How to disconnect cables from motors is axes 3, 4, 5 and 6. detailed in sections: • Removing motors on page 305 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 271 Stop the air from the Foundry Prime air hose. Insert a screw in the hose and a lock it with a hose clamp. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 272 Use an extra washer if the screw does bottom. Tightening torque: 30 Nm. xx1100000565 xx1100000566 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 273 Rotating lifting point, 2 pcs Roundsling around wrist unit Length: 1.5 m. Roundsling attached to arm house, 2 pcs Length: 1.5 m. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 274 It may be necessary to turn the gear by ro- tating the motor pinion with a rotation tool, motor beneath the motor cover. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 275 Foundry Prime paint coat of the robot. See Cut the paint or surface on the robot before replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 276 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 277: Replacing Complete Tubular Shaft Unit
These procedures include references to the tools quired. See references to these proced- required. ures in the step-by-step instructions be- low. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 278 How to drain the oil from the gearbox is described in section: • Changing the oil, axis-4 gearbox on page 177 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 279 Remove motors axes 4, 5 and 6. How to remove motors is described in section: • Removing motors on page 305 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 280 CAUTION Remaining oil will drain out from the gear- box cavity when the tubular shaft is lifted out. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 281 D Cylindrical pin (2 pcs) CAUTION The robot arm tube weighs 65 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 282 Parts: • A: Tubular shaft unit • B: Attachment screws M6x16 qual- ity 8.8-A2F (2 pcs) • C: Bracket Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 283 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 284: Replacing Wrist Unit
- IRB 2600. Measuring tool For adjusting the play. Standard toolkit Content is defined in section Standard tools on page 393. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 285 Use this procedure to remove the wrist unit. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 286 Clean the joints that have been opened. See Cut the paint or surface on the robot before re- placing parts on page 201 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 287 IRB 4600 -60/2.05 6 ±0,5 xx1600000702 Clean all assembly surfaces. Remove any painting from the assembly sur- faces, with a knife. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 288 Measuring the play, axis 6 on page 292 Perform a leak-down test. Performing a leak-down test on page 196. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 289 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 290: Measuring The Play, Axis 5
Fit the measuring tool, play to the turning Article number is specified in Required disc. equipment on page 290. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 291 The maximum play allowed at the given reading the dial indicator. distance from the center of axis 5 is, for robot version: • IRB 4600 -60/2.05 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 292: Measuring The Play, Axis 6
Fit the measuring tool, play to the turning Article number is specified in Required disc. equipment on page 292. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 293 Values for robot versions IRB 4600 -60/2.05 • A: Measuring tool, play • B: 100 mm • C: 100 mm • F: 50N Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 294 The maximum play allowed at the given by reading the dial indicator. distance (B) from the center of axis 6 is, for robot version: • IRB 4600 -60/2.05 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 295: Lower Arm
Attachment screws M8x40 quality Steel 12.9 Gleitmo (19 pcs) Frame Axis-2 gearbox Washer (18 pcs) Attachment screws M12x50 quality Steel 12.9 Gleitmo (18 pcs) Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 296 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 297 Cut the paint or surface on the robot before replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 298 Remove the attachment screws and wash- ers that secure the lower arm to the axis-2 gearbox. xx1800000935 Remove the lower arm. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 299 A: Lifting lug Secure the lower arm with a roundsling in an overhead crane and lift it to the robot. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 300 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 301: Frame And Base
Frame and base in Product manual, spare parts - IRB 2600. Standard toolkit Content is defined in section Standard tools on page 393. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 302 Remove the bracket and stop pin. See the figure in • Location of stop pin axis 1 on page 301 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 303 Foundry Prime paint coat of the robot. See Cut the paint or surface on the robot before replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 304 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 305: Motors
This procedure describes how to remove motors on all axes of the robot. Location of axis-1 and axis-2 motors (Foundry Prime) The figure shows axis-1 motor on IRB 4600 Foundry Prime. xx1100000083 Attachment screws M5x16, quality Steel 8-A2F (7 pcs)
Page 306 Tightening torques and attachment screws on page 318 Axis-3 motor Axis-4 motor Axis-5 motor Axis-6 motor O-ring (axis-4, axis-5 and axis-6) Armhouse Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 307 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 308 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 309 The gearbox has to be drained before in section: removing the motor. • Changing the oil, axis-2 gearbox on page 167 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 310 See the paint or surface on the robot before repla- cing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 312 Note motor flange. Always use removal tools in pairs diag- onal to each other. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 313 Check that the o-ring also is removed. It might motors (Foundry Prime) on stay in the armhouse when the motor is re- page 305 moved. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 314: Refitting Motors
See the Spare parts manual on myABB business portal (www.myportal.abb.com). Location of axis-1 and axis-2 motors, (Foundry Prime) The figure shows motor axis1 on IRB 4600 Foundry Prime. xx1100000083 Attachment screws M5x16, quality Steel 8-A2F (7 pcs)
Page 315 Tightening torques and attachment screws on page 318 Axis-3 motor Axis-4 motor Axis-5 motor Axis-6 motor O-ring (axis-4, axis-5 and axis-6) Armhouse Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 316 Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Loctite 574 12340011-116 Brush Foundry Prime touch up kit 3HAC035355-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 317 Release the axis-2 brake to be sure that the lower arm rests in the end position. xx1100000548 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 318 Motor axis 2 Motor axis 3 Flange thickness Attachment screws Flange thickness Attachment screws 18.5 mm M10x40 15 mm M8x35 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 319 A: Correct position of o-ring • B: Incorrect position of o-ring ! Replace with a new o-ring if damaged! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 320 Clean the joints that have been opened. See Cut the paint or surface on the robot before replacing parts on page 201 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 321 Make sure that the wire exit holes of motor axis 3 are in the correct position. See illustration! xx0900000300 Parts: • A: Wire exit holes, motor axis 3 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 322 Refit the connection box (if it has been re- motors, (Foundry Prime) on moved). page 314 Note Make sure that the o-ring is in place! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 323 If the gasket is damaged, it need to be replaced. Make sure that the gasket on the cover on the armhouse is intact. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 324 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 325: Adjusting The Play Of Axis 4, 5 And 6 Motors
Push or tap the motor in radial direction so that the play becomes minimal within one motor turn, without the gear "chewing". Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 326: Gearboxes
Gearbox axis 1 Washer (21 pcs) Attachment screws M8x80 quality Steel 12.9 Gleitmo (21 pcs) Radial sealing Sealing ring Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 327 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 328 How to drain the oil from the gearbox is described in section: • Changing the oil, axis 1 gearbox on floor mounted robots on page 153 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 329 Remove the complete arm system from the Removing the base on page 259. base and lay down the robot on its side. xx1800000593 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 330 Guide pin, M8x150: 3HAC15520-2 Always use guide pins in pairs! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 331 If necessary use removal tools to remove Always use removal tools in pairs diagon- the gearbox. al to each other. xx1800000791 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 332 Fit a lifting lug in the uppermost hole for the base attachment screws. xx0800000440 A Roundsling B Lifting lug C Uppermost base attachment hole D Axis-1 gearbox Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 333 Fit the guide for the gear on top of the pro- Guide for reduction gear: 3HACxxx. tection tube. It protects the radial sealing from being damaged during refitting. xx1800000795 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 334 Remove the guide pins from the frame and secure the remaining two screws. xx1800000790 • 35 Nm Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 335 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 336: Replacing Gearbox Axis 2
Attachment screws M12x50 quality Steel 12.9 Gleitmo (15 pcs) Washers (15 pcs) Sleeve (delivered with gearbox) Gearbox axis 2 O-ring Frame Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 337 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 338 The figure shows IRB 2600 but the position of in the figure. the robot is correct. Upper arm should rest on the axis-3 damper. xx1200000068 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 339 205 kg All lifting accessories used must be sized accordingly. Attach a roundsling around the upper arm house. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 340 CAUTION The gearbox weighs 51 kg All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 341 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 342 Secure the gearbox with a roundsling in an overhead crane or similar. Release the brakes of the axis 2 motor. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 343 Gleitmo 12.9 (18 pcs) box. Tightening torque: 110 Nm. xx1800000935 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 344 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 345: Replacing Gearbox Axis 3
Guide pins M8 (2 pcs) Used to guide the gearbox and the upper arm during removal/refitting. Rotation tool 3HAB7887-1 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 346 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 347 Cut the paint or surface on the robot before replacing parts on page 201. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 348 3 to the armhouse! CAUTION The robot upper arm weighs 140 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 349 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 350 Location of gearbox axis 3 on page 345 Tightening torque: 35 Nm. Remove the guide pins and replace them with the remaining attachment screws. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 351 Make sure that the armhouse cover is tightly fitted. If there is a gap between the cover and the robot, seal with Sikaflex 521 FC. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 352 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 353: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 354: Calibration Methods
FlexPendant. If no data is found related to standard calibration, Calibration Pendulum is used as default. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 355 Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Two different routines are available for the Calibration Pendulum method: •...
Page 356: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 357: Synchronization Marks And Axis Movement Directions
Synchronization marks, IRB 4600 IRB 4600-60/2.05 xx0800000312 Synchronization mark, axis 1 Synchronization mark, axis 2 Synchronization mark, axis 3 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 358 Synchronization mark, axis 6 The two tips of the arrows should be inside the corresponding groove on the tilt housing when in synchronization position. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 359: Calibration Movement Directions For All Axes
Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 360: Updating Revolution Counters
At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 361 Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 362 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 363 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 380. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 364: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 365 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 366 To calibrate a suspended robot with the fine calibration routine, the robot must first be taken down and then be mounted standing on the floor. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 367: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 368 Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on calibration tool size). • Straightness within 0.005 mm. xx1500000951 Outer diameter Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 369: Installation Locations For The Calibration Tools
This is shown in the figure. xx1600000641 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 370 Foundry Prime) for the bushing. Protective plug on turning disc 3HAC057511-001 Only on IRB 4600 - 20/2.50. Replace if damaged or missing. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 371: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 372 Use a clean cloth. Note The calibration method is exact. Dust, dirt or color flakes will affect the calibration value. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 373 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 374 To be able to run Axis Calibration SafeMove needs to be unsynchronized. The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 375 Press Acknowledge to continue Axis Calibration procedure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 376 Replace the cover with new spare part, if missing or damaged. xx1600002102 Protection cover and plug set: . 3HAC060730-001 (protection type Foundry Prime) Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 378: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 379: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Remove any calibration equipment from the robot. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 380: Checking The Synchronization Position
If they do not, up- ization position for axes on page 357 date the revolution counters. Updating revolution counters on page 360. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 381: Decommissioning
These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 382: Environmental Information
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 383 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 384: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 385: Reference Information
7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 386: Applicable Standards
Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 387 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 388: Unit Conversion
2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 389: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 390 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 391 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 392: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 393: Standard Tools
Socket head cap no: 6, socket 1/2" bit L 20 mm Socket head cap no: 8, socket 1/2" bit L 20 mm Small cutting plier T-handle with ball head Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 394: Special Tools
The following table specifies the calibration equipment required when calibrating the robot with the alternative method, Levelmeter Calibration. Description Art. no. Note Angle bracket 68080011-LP Calibration bracket 3HAC13908-9 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 395 Description Art. no. Note Turning tool (includes lifting instruction) 3HAC034766-001 Valid for other designs than type C. Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 396 The tools are specified directly in concerned instructions. Description Article no. Guide for reduction gear 3HACxxx Used to guide axis-1 gear and frame during refitting. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 397: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
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Page 399: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
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Page 401: Circuit Diagram
3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 402 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - Product.ProductName 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 403: Index
17 climbing on robot, 23 Lithium Cold environments, 93 disposal, 382 connecting the robot and controller, cabling, 94 loads on foundation, 53 connection Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 404 17 storing on FlexPendant, 361 system parameter updating, 360 Gravity Alpha, 66 risk of tipping, 60 Gravity Beta, 65 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 405 270, 274 torques on foundation, 53 troubleshooting oil spills, 191 turning replacing, 143 accessory, 64 zero position updating revolution counters, 360 checking, 380 Product manual - IRB 4600 Foundry Prime 3HAC040585-001 Revision: M © Copyright 2013-2018 ABB. All rights reserved.
Page 408 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2013-2018 ABB. All rights reserved. Specifications subject to change without notice.

ABB IRB 4600 Foundry Prime Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Part Lists

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