Abb irb 4400 product manual

Feb 8, The new interface is a complex system with many different parts, hardware as well as software. Rapid Reference Manual,. Morphological Analysis of. Industrial Robots Configuration In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.

This document and parts thereof must not be reproduced or copied without. Apr 1, The IRC5 controller includes An automatic deburring system using IRB manipulator is designed to clean ISO M6. Hose guide for NW23 hose. Shingling is currently a very manual labor intensive process. Shingles are purchased as rectangular pieces of All of these were provided by the dFAB Technical Data. Length: 1. Width: 1. Weight: 3. SK All Rights Reserved.

Designed by Templatic. Home Copyright Privacy Contact. Abb Maintenance Manual Irb Sponsored High Speed Downloads. Product specification - IRB Oct 17, Mechanical Maintenance non-Paint Robots Topics include. Mechanical Maintenance non-Paint Robots rev Page 19 The robot can be manually operated in any one of the following ways: - Axis-by-axis, i.

Page External Axes Signals can be assigned to special system functions, such as program start, so as to be able to control the robot from an external panel or PLC. However this requires optional software, see Product Specification RobotWare. EN accepts one channel circuit without monitoring, instead the design is made to comply with category 3 according to EN , where the demand for redundancy is founded. These windows control a number of different functions: - Jogging manual operation.

Page 37 Figure 24 The mechanical interface, mounting flange dimensions in mm. A warning is given at power on when one of the batteries is empty. The maintenance intervals depends on the use of the robot. For detailed information on maintenance procedures, see Maintenance section in the Product Manual. Page 47 0. Velocity Axis no. Program can be decided when configuring the robot. The same numbers are used here as in the Specification form.

For software options, see Product Specification RobotWare. Designs with 1, 2 or 3 adjustable switches are available. Page 57 Stop lugs for restricting the working range. Figure 35 illustrates the mounting positions of the stops. Page Control System The cabinet extension is opened via a front door and it has no floor.

The upper part of the standard cabinet is therefore accessible. This option cannot be combined with option Page 59 External, i. All necessary cabling, including flange, connectors, sealing strips, screws, etc. External enclosure is not supplied. See Figure Specification of maintenance intervals 3. Maintenance schedule 3. Maintenance schedule General The robot must be maintained regularly to ensure proper function.

The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component. Page 92 3 Maintenance 3. Maintenance schedule Continued Activities and intervals Foundry Prime application Robots working with water jet cleaning and that have the special tightness for this application require special maintenance for proper function.

The maintenance must be done according to the maintenance schedule in the Product Manual and the following additional maintenance. Page General Maintenance Activities 3 Maintenance 3. Inspection of mechanical stop, axis 1 3. Inspection of mechanical stop, axis 1 Location of mechanical stop The mechanical stop on axis 1 is located on the frame as shown in the figure below.

Page 94 3 Maintenance 3. Inspection of mechanical stop, axis 1 Continued Inspection The procedure below details how to inspect the mechanical stop on axis 1 If the mechanical stop has been deformed after a hard collision, it must be replaced! Inspection of air hoses Foundry Prime 3. Inspection of air hoses Foundry Prime General The air hoses on Foundry Prime robots must be inspected for leakage every six month.

Required equipment Equipment, etc. Note Leak detection spray Pressure gauge cut off valve Procedure Replacement of battery pack, measuring system 3.

Replacement of battery pack, measuring system Location of battery pack The battery pack is fit to the serial measurement unit, located inside the base. To access the unit and battery pack, the rear cover plate shown in the figure below must be removed. Page 97 3 Maintenance 3.

Replacement of battery pack, measuring system Continued Replacement, battery pack The procedure below details how to replace the battery pack in the serial measurement unit. Page Cleaning Of Manipulator 3 Maintenance 3. Cleaning of manipulator 3. Cleaning of manipulator General Depending on the protection class, different methods of cleaning the manipulator are allowed.

Oil in gearbox unit, axis 3. Oil in gearbox unit, axis General The oil in the gearbox unit, axis , is normally not changed. This section specifies the oil permitted in the unit. Inspection of oil levels 3. Inspection of oil levels Location of oil plugs, axes 2 and 3 The oil plug, filling for the gearbox unit, axes 2 and 3, is located as shown in the figure below.

The figure shows the location of the axisside and is the same on the opposite side. Page 3 Maintenance 3.

Page When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified by the manufacturer! If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further instructions! Required oil level: 4 mm to the edge of the oil plug hole. Fill with lubricating oil, if necessary. Type of oil is detailed in section Oil change, gearbox axis 4 on page Oil change, gearbox axis 4 3.

Oil change, gearbox axis 4 Location of oil plugs The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located as shown in the figure below. Remove the upper oil plug, filling. Shown in the figure Location of oil plugs on page Fill the gearbox with lubricating oil. Amount and art. When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains quicker than cold oil.

Page Repair 4 Repair 4. Introduction 4 Repair 4. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e. Page General Procedures 4 Repair 4. Performing a leak-down test 4. Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested.

This is done in a leak-down test. Mounting instructions for bearings 4. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the robot.

Equipment Equipment, etc. Mounting instructions for seals 4. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Rotating seals The procedure below details how to fit rotating seals. Page If the flange surfaces are defective, the parts may not be used because leakage could occur.

Clean the surfaces properly and in accordance with ABB recommendations. Distribute the sealing compound evenly over the surface, preferably with a brush. Page Complete Robot 4 Repair 4. Replacement of cable harness, axes 4. Replacement of cable harness, axes Location of cable harness, axes The cable harness of axes is located throughout the axis 1 of the robot as shown in the figure below.

Page 4 Repair 4. Replacement of cable harness, axes Continued Location of cable harness, view X-X The cable guides in the middle of axis 1 are located as shown in the figure below. Connectors at motor 1: R3. MP1, R3. Connection box, motor 2. Replacement of cable harness, axes Continued Equipment, etc. Spare part no. Note Circuit diagram See chapter Circuit diagram in the Product manual, reference infor- mation. Calibration Pendulum General calibration Instruction information is included in section Calibration information on page Replacement of cable harness, axes Continued Refitting, cabling axes The procedure below details how to refit the cable harness to axes Replacement of cable harness, axes Location of cable harness, axes The cable harness of axes is located throughout the robot as shown in the figure below.

The figures show the robot model IRB But the location of the cable harness axes on the IRB S is basically the same. Calibration Pendulum Calibration is detailed in a Instruction separate calibration manual, enclosed with the calibration tools. Loosen the cable brackets A between gearboxes 2 and 3 and cut the strap around them. Feed the cabling and the air hose, if any, up through axis 1. Replacement of cable harness, axes Continued Connection box, upper arm The figure below shows the location of the motors, connectors and cabling in the upper arm connection box.

MP4 Connector R3. FB4 Axis 5 motor Connector R3. MP5 Connector R3. Check the position of the three gaskets, located Part no. Replace them if damaged. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page Replacement of complete arm system 4. Replacement of complete arm system Location of complete arm system The complete arm system includes the lower arm and the complete upper arm, as shown in the figure below.

The figure shows the IRB A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference Replacement of complete arm system Continued Spare part Equipment, etc. Note Other tools and These procedures include procedures may be references to the tools required. See references required.

Move the upper arm into a resting position against the lower arm. Lock the upper arm in this position with securing slings around the lower and upper arm A , as shown in the figure to the right. Replacement of complete arm system Continued Refitting, complete arm system The procedure below details how to refit the complete arm system to the robot. The following procedure also applies to the IRB S. Secure the arm system to the gearbox axis 2 10 pcs, M16x Tightening with the attachment screws and friction torque: Nm.

Shown in the figure Location of Make sure both V-rings are seated properly! Page Upper Arm 4 Repair 4. Replacement of complete upper arm 4. Replacement of complete upper arm Location of upper arm The complete upper arm includes the wrist unit and is located as shown in the figure below. Replacement of complete upper arm Continued Required equipment Spare part Equipment, etc.

Move the upper arm to a horizontal position. Secure the weight of the upper arm with the lifting slings and a crane. Remove the tie rod. Detailed in section Removal, tie rod on page Lower the upper arm into mounting position. Refit both shaft ends. Shown in the figure Location of upper arm on page Part no. Refit the calibration plate, axis 3. Refit the connection box. Replacement of wrist unit 4.

Replacement of wrist unit Location of wrist unit The wrist unit is located in the upper arm as shown in the figure below. The illustration shows the IRB Page This component includes a complete unit comprising motors and gearboxes. It is a replacement unit of complex design and should not normally be serviced on-site.

Instead it should be sent to ABB for service. ABB recommends its customers to carry out only the following servicing and repair work on this unit. Instead it should be sent to ABB for service etc. Apply flange sealing to the surface of the Specified in Required equipment on wrist that will seal against the upper arm page Sealing surface shown in the figure Location of wrist unit on page Tighten the attachment screws and washers A.

Tightening torque: 34 Nm. Check the play by moving axes 5 and 6 by hand. Replacement of arm house unit, axis 4 4. Replacement of arm house unit, axis 4 Location of arm house unit The arm house unit includes the axis 4 housing and the upper arm tube.

It is located as shown in the figure below. Replacement of arm house unit, axis 4 Continued Replacement, arm house unit The procedure below details how to replace the arm house unit. The complete arm house unit weighs kg! All lifting equipment used must be dimensioned accordingly! Replacement of mechanical stop, axis 4 4. Replacement of mechanical stop, axis 4 Location of mechanical stop The mechanical stop of axis 4 is located in the upper arm as shown in the figure below. Replacement of mechanical stop, axis 4 Continued If the mechanical stop has been deformed after a hard collision, it must be replaced!

Fit the mechanical stop to the axis 4 with its Shown in the figure Location attachment screws. Replacement of signal cabling, upper arm option 4. Replacement of signal cabling, upper arm option Location of signal cabling, upper arm The signal cabling option runs along the upper arm as shown in the figure below.

Replacement of signal cabling, upper arm option Continued Removal, signal cabling upper arm The procedure below details how to remove the signal cabling from the upper arm.

Refit the upper arm bracket to the upper arm. Location of the bracket is shown in the figure Location of signal cabling, upper arm on page Move axis 4 from one extreme limit to the other and back again. Measuring the play, axis 5 4. Measuring the play, axis 5 General After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be checked to ensure the repetition accuracy of the robot positioning.

The procedure for axis 5 is detailed below. Apply load F in one direction, as shown in the figure to the right. Different load and distances for the different robot versions, as specified to the right! Apply load F in the opposite direction, as shown in the figure to the right.

Measuring the play, axis 6 4. Measuring the play, axis 6 General After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed below. Attach a weight m at a distance B from the wrist flange, in order to avoid the effects of play on axis 5.

Different weight and distance for the different robot versions, as specified to the right! Page Lower Arm 4 Repair 4. Replacement of lower arm 4. Replacement of lower arm Location of lower arm The lower arm is located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.

Replacement of lower arm Continued V-ring between lower arm and gearbox axis 3 Required equipment Equipment, etc. Remove the complete upper arm. Detailed in section Removal of complete upper arm. Attach a crane to the lower arm and unload the weight. Remove the balancing device. Detailed in section Replacement of balancing device on page Refit the balancing device. Detailed in section Refitting of balancing device on page Refit the upper arm. Detailed in section Refitting, upper arm on page Refit the cabling.

Detailed in section Refitting, cabling axes on page Replacement of tie rod 4. Replacement of tie rod Location of tie rod The tie rod is located as shown in the figure below. Figure shows the IRB Replacement of tie rod Continued Required equipment Spare part Equipment, etc. Remove the two attachment screws. Shown in the figure Location of tie rod on page Remove the two washers, o-rings and sealings, Shown in the figure Location outside from the tie rod. Make sure all safety requirements are met when performing the first test run.

The bearing of the parallel arm is shown in the enlarged view. Loosen the attachment screws A so that the cabling can be moved slightly. Remove the 10 attachment screws and the washer that holds the parallel arm to gearbox axis 3. Refit the washer and the 10 attachment 10 pcs. M16x80, Reused screws may be used, providing they are lubricated as detailed in section Screw Joints in the Product manual, Page Frame And Base 4 Repair 4.

Replacement of balancing device 4. Replacement of balancing device Location of balancing device The balancing device is located as shown in the figure below. Replacement of balancing device Continued Required equipment Equipment, etc. Replacement of balancing device Continued Removal, balancing device The procedure below details how to remove the balancing device.

For example, attempting to open the balancing device is potentially lethal! Remove the two securing screws A , located at the fork of the balancing device. Also remove the plate C which secures that the bushing D is held in position. Remove the four attachment screws, Shown in the figure Location of bracket from the bracket at the right side balancing device on page ! Replacement of balancing device Continued Refitting of balancing device The procedure below details how to refit the balancing device.

Turn off all electric power, hydraulic and Replacement of serial measurement unit 4. Replacement of serial measurement unit Location of serial measurement unit The serial measurement unit is located inside the base of the robot, behind the rear cover, as shown in the figure below. Replacement of serial measurement unit Continued Required equipment Equipment, etc. Remove the connectors from the board.