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IRB 4600 Foundry Prime
ABB IRB 4600 Foundry Prime Product Manual
ABB IRB 4600 Foundry Prime Product Manual
Table of content
Contents
Table Of Contents
Table Of Contents
Table Of Contents
Overview of this manual
Product manual - IRB
Product documentation
How to read the product manual
Important information about robots with protection type Foundry Prime
Safety
Protective stop and emergency stop
Safety actions
Emergency release of the robot axes
Make sure that the main power has been switched off
Safety risks
Moving robots are potentially lethal
First test run may cause injury or damage
Work inside the working range of the robot
Enabling device and hold-to-run functionality
Risks associated with live electric parts
The unit is sensitive to ESD
Hot parts may cause burns
Safety risks related to pneumatic/hydraulic systems
Safety risks with pressure relief valve
Brake testing
Safety risks during handling of batteries
Safety risks during work with gearbox lubricants (oil or grease)
Safety signals and symbols
Safety symbols on product labels
Installation and commissioning
Installation and operational requirements for Foundry Prime robots
Unpacking
Surface inspection before start-up - Foundry Prime
Working range and type of motion
Risk of tipping/stability
On-site installation
Lifting and turning a suspended mounted robot
Setting the system parameters for a suspended or tilted robot
Manually releasing the brakes
Orienting and securing the robot
Fitting equipment on robot
Loads fitted to the robot, stopping time and braking distances
Installation of signal lamp (option)
Restricting the working range
Mechanically restricting the working range of axis 1
Installing options
Robot in hot environments
Robot in cold environments
Electrical connections
Customer connection on robot
Customer connections on upper arm
Additional installation (Foundry Prime)
Commissioning (Foundry Prime)
Maintenance
Introduction for Foundry Prime robots
Maintenance schedule
Expected component life
Inspection activities
Inspecting the oil level, axis 2 gearbox
Inspecting the oil level, axis 3 gearbox
Inspecting the oil level, axis 4 gearbox
Inspecting oil level, gearbox axes 5 - 6
Inspecting the cable harness
Inspecting information labels
Inspecting the mechanical stop pin, axis 1
Inspecting additional mechanical stops
Inspecting dampers
Inspecting the leak proof o-ring and pressure relief valves
Inspecting Signal lamp (option)
Inspection of air hoses (Foundry Prime)
Inspection of surface treatment (Foundry Prime)
Replacement activities
Changing the oil, axis 1 gearbox on floor mounted robots
Changing the oil, axis-1 gearbox on suspended robots
Changing the oil, axis-2 gearbox
Changing the oil, axis-3 gearbox
Changing the oil, axis-4 gearbox
Changing oil, axes-5 and -6 gearboxes
Replacing SMB battery
Analysis activities
Cleaning activities
Repair
General procedures
Mounting instructions for bearings
Mounting instructions for seals
Cut the paint or surface on the robot before replacing parts
The brake release buttons may be jammed after service work
Complete robot
Refitting the complete cable harness
Replacement of air nipples and hoses (Foundry Prime)
Replacing SMB unit
Replacing the brake release board
Replacing the base
Upper arm
Replacing complete tubular shaft unit
Replacing wrist unit
Measuring the play, axis 5
Measuring the play, axis 6
Lower arm
Frame and base
Motors
Refitting motors
Adjusting the play of axis 4, 5 and 6 motors
Gearboxes
Replacing gearbox axis 2
Replacing gearbox axis 3
Calibration
Calibration methods
When to calibrate
Synchronization marks and axis movement directions
Calibration movement directions for all axes
Updating revolution counters
Calibrating with Axis Calibration method
Calibration tools for Axis Calibration
Installation locations for the calibration tools
Axis Calibration - Running the calibration procedure
Calibrating with Calibration Pendulum method
Verifying the calibration
Checking the synchronization position
Decommissioning
Environmental information
Scrapping of robot
Reference information
Applicable standards
Unit conversion
Screw joints
Weight specifications
Standard tools
Special tools
Lifting accessories and lifting instructions
Spare part lists
Circuit diagram
Index
ROBOTICS
Product manual
IRB 4600 Foundry Prime
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This manual is suitable for:
IRB 4600 Foundry Prime
