ABB IRB 4600 Foundry Prime User manual

Category
Robotics
Type
User manual
ROBOTICS
Product manual
IRB 4600 Foundry Prime
Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012
Product manual
IRB 4600 Foundry Prime - 60/2.05
IRC5
Document ID: 3HAC040585-001
Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Specifications subject to change without notice.
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.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2013-2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation ....................................................................................................................
15How to read the product manual ......................................................................................................
16Important information about robots with protection type Foundry Prime ......................................
171 Safety
171.1 General safety information ..................................................................................
171.1.1 Limitation of liability .................................................................................
191.1.2 Protective stop and emergency stop ...........................................................
201.2 Safety actions ...................................................................................................
201.2.1 Fire extinguishing ....................................................................................
211.2.2 Emergency release of the robot axes ..........................................................
221.2.3 Make sure that the main power has been switched off ....................................
231.3 Safety risks ......................................................................................................
231.3.1 Safety risks during installation and service work on robots ..............................
251.3.2 Moving robots are potentially lethal ............................................................
261.3.3 First test run may cause injury or damage ....................................................
271.3.4 Work inside the working range of the robot ..................................................
281.3.5 Enabling device and hold-to-run functionality ...............................................
291.3.6 Risks associated with live electric parts .......................................................
311.3.7 The unit is sensitive to ESD .......................................................................
321.3.8 Hot parts may cause burns .......................................................................
331.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
341.3.10 Safety risks with pressure relief valve .........................................................
351.3.11 Brake testing ..........................................................................................
361.3.12 Safety risks during handling of batteries ......................................................
371.3.13 Safety risks during work with gearbox lubricants (oil or grease) .......................
391.4 Safety signals and symbols .................................................................................
391.4.1 Safety signals in the manual ......................................................................
411.4.2 Safety symbols on product labels ...............................................................
472 Installation and commissioning
472.1 Introduction ......................................................................................................
482.2 Installation and operational requirements for Foundry Prime robots ............................
522.3 Unpacking .......................................................................................................
522.3.1 Pre-installation procedure .........................................................................
562.3.2 Surface inspection before start-up - Foundry Prime .......................................
572.3.3 Working range and type of motion ..............................................................
602.3.4 Risk of tipping/stability .............................................................................
612.4 On-site installation ............................................................................................
612.4.1 Lifting robot with roundslings ....................................................................
642.4.2 Lifting and turning a suspended mounted robot ............................................
652.4.3 Setting the system parameters for a suspended or tilted robot .........................
692.4.4 Manually releasing the brakes ...................................................................
722.4.5 Orienting and securing the robot ................................................................
762.4.6 Fitting equipment on robot ........................................................................
822.4.7 Surface inspection before start-up - Foundry Prime .......................................
832.4.8 Loads fitted to the robot, stopping time and braking distances .........................
842.4.9 Installation of signal lamp (option) ..............................................................
852.5 Restricting the working range ..............................................................................
852.5.1 Axes with restricted working range .............................................................
862.5.2 Mechanically restricting the working range of axis 1 ......................................
892.6 Installing options ...............................................................................................
892.6.1 Installing an expansion container ...............................................................
922.7 Robot in hot environments ..................................................................................
922.7.1 Start of robot in hot environments ..............................................................
Product manual - IRB 4600 Foundry Prime 5
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Table of contents
932.8 Robot in cold environments .................................................................................
932.8.1 Start of robot in cold environments ............................................................
942.9 Electrical connections ........................................................................................
942.9.1 Robot cabling and connection points ..........................................................
962.9.2 Customer connection on robot ...................................................................
992.9.3 Customer connections on upper arm ..........................................................
1012.10 Additional installation (Foundry Prime) ..................................................................
1012.10.1 Installation of IRB 4600 Foundry Prime in a water jet application ......................
1052.10.2 Commissioning (Foundry Prime) ................................................................
1073 Maintenance
1073.1 Introduction ......................................................................................................
1083.2 Introduction for Foundry Prime robots ...................................................................
1093.3 Maintenance schedule .......................................................................................
1093.3.1 Specification of maintenance intervals ........................................................
1103.3.2 Maintenance schedule .............................................................................
1123.3.3 Expected component life .........................................................................
1133.4 Inspection activities ...........................................................................................
1133.4.1 Inspecting oil level, axis 1 gearbox .............................................................
1193.4.2 Inspecting the oil level, axis 2 gearbox ........................................................
1223.4.3 Inspecting the oil level, axis 3 gearbox ........................................................
1253.4.4 Inspecting the oil level, axis 4 gearbox ........................................................
1273.4.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................
1313.4.6 Inspecting the cable harness .....................................................................
1333.4.7 Inspecting information labels .....................................................................
1353.4.8 Inspecting the mechanical stop pin, axis 1 ...................................................
1393.4.9 Inspecting additional mechanical stops .......................................................
1413.4.10 Inspecting dampers .................................................................................
1433.4.11 Inspecting the leak proof o-ring and pressure relief valves ..............................
1463.4.12 Inspecting Signal lamp (option) ..................................................................
1483.4.13 Inspection of air hoses (Foundry Prime) ......................................................
1503.4.14 Inspection of surface treatment (Foundry Prime) ...........................................
1513.5 Replacement activities .......................................................................................
1513.5.1 Type of lubrication in gearboxes ................................................................
1533.5.2 Changing the oil, axis 1 gearbox on floor mounted robots ...............................
1603.5.3 Changing the oil, axis-1 gearbox on suspended robots ...................................
1673.5.4 Changing the oil, axis-2 gearbox ................................................................
1713.5.5 Changing the oil, axis-3 gearbox ................................................................
1773.5.6 Changing the oil, axis-4 gearbox ................................................................
1813.5.7 Changing oil, axes-5 and -6 gearboxes ........................................................
1853.5.8 Replacing SMB battery .............................................................................
1903.6 Analysis activities ..............................................................................................
1903.6.1 Analyzing the water content in gearbox oil ...................................................
1913.7 Cleaning activities .............................................................................................
1913.7.1 Cleaning the IRB 4600 Foundry Prime .........................................................
1954 Repair
1954.1 Introduction ......................................................................................................
1964.2 General procedures ...........................................................................................
1964.2.1 Performing a leak-down test ......................................................................
1974.2.2 Mounting instructions for bearings .............................................................
1994.2.3 Mounting instructions for seals ..................................................................
2014.2.4 Cut the paint or surface on the robot before replacing parts ............................
2034.2.5 The brake release buttons may be jammed after service work .........................
2044.3 Complete robot .................................................................................................
2044.3.1 Removing the complete cable harness ........................................................
2174.3.2 Refitting the complete cable harness ..........................................................
2334.3.3 Replacement of air nipples and hoses (Foundry Prime) ..................................
2454.3.4 Replacing SMB unit .................................................................................
6 Product manual - IRB 4600 Foundry Prime
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Table of contents
2524.3.5 Replacing the brake release board .............................................................
2574.3.6 Replacing the base ..................................................................................
2674.4 Upper arm .......................................................................................................
2674.4.1 Replacing the complete upper arm .............................................................
2774.4.2 Replacing complete tubular shaft unit .........................................................
2844.4.3 Replacing wrist unit .................................................................................
2904.4.4 Measuring the play, axis 5 .........................................................................
2924.4.5 Measuring the play, axis 6 .........................................................................
2954.5 Lower arm .......................................................................................................
2954.5.1 Replacing the lower arm ...........................................................................
3014.6 Frame and base ................................................................................................
3014.6.1 Replacing stop pin axis 1 ..........................................................................
3054.7 Motors ............................................................................................................
3054.7.1 Removing motors ....................................................................................
3144.7.2 Refitting motors ......................................................................................
3254.7.3 Adjusting the play of axis 4, 5 and 6 motors .................................................
3264.8 Gearboxes .......................................................................................................
3264.8.1 Replacing gearbox axis 1 ..........................................................................
3364.8.2 Replacing gearbox axis 2 ..........................................................................
3454.8.3 Replacing gearbox axis 3 ..........................................................................
3535 Calibration
3535.1 Introduction to calibration ...................................................................................
3535.1.1 Introduction and calibration terminology ......................................................
3545.1.2 Calibration methods .................................................................................
3565.1.3 When to calibrate ...................................................................................
3575.2 Synchronization marks and axis movement directions .............................................
3575.2.1 Synchronization marks and synchronization position for axes .........................
3595.2.2 Calibration movement directions for all axes ................................................
3605.3 Updating revolution counters ...............................................................................
3645.4 Calibrating with Axis Calibration method ...............................................................
3645.4.1 Description of Axis Calibration ..................................................................
3675.4.2 Calibration tools for Axis Calibration ...........................................................
3695.4.3 Installation locations for the calibration tools ...............................................
3715.4.4 Axis Calibration - Running the calibration procedure ......................................
3785.5 Calibrating with Calibration Pendulum method ........................................................
3795.6 Verifying the calibration ......................................................................................
3805.7 Checking the synchronization position ..................................................................
3816 Decommissioning
3816.1 Introduction ......................................................................................................
3826.2 Environmental information ..................................................................................
3846.3 Scrapping of robot .............................................................................................
3857 Reference information
3857.1 Introduction ......................................................................................................
3867.2 Applicable standards .........................................................................................
3887.3 Unit conversion .................................................................................................
3897.4 Screw joints ....................................................................................................
3927.5 Weight specifications .........................................................................................
3937.6 Standard tools ..................................................................................................
3947.7 Special tools ....................................................................................................
3977.8 Lifting accessories and lifting instructions ..............................................................
3998 Spare part lists
3998.1 Spare part lists and illustrations ...........................................................................
Product manual - IRB 4600 Foundry Prime 7
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Table of contents
4019 Circuit diagram
4019.1 Circuit diagrams ................................................................................................
403Index
8 Product manual - IRB 4600 Foundry Prime
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Table of contents
Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The robot described in this manual has the protection type Foundry Prime.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by 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.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Safety
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Maintenance
Continues on next page
Product manual - IRB 4600 Foundry Prime 9
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Overview of this manual
ContentsChapter
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
Calibration procedures and general information about calibration.Calibration
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards etc.
Reference information
Complete spare part list and complete list of robot components,
shown in exploded views.
Spare part / part list
Detailed illustrations of the robot with reference numbers to the
part list.
Exploded views
Reference to the circuit diagram for the robot.Circuit diagram
References
Document IDReference
3HAC033453-001Product manual - IRB 4600
3HAC049108-001Product manual, spare parts - IRB 4600
3HAC032885-001Product specification - IRB 4600
3HAC029038-003Circuit diagram - IRB 4600
3HAC031045-001Operating manual - General safety information
i
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC027098-001Operating manual - Emergency safety information
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC020738-001Operating manual - Troubleshooting IRC5
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-001Operating manual - Service Information System
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
3HAC051016-001Application manual - Additional axes and stand alone controller
3HAC050996-001Application manual - Electronic Position Switches
3HAC030421-001Application manual - CalibWare Field 5.0
Contact ABB local sales
organization
List of approved cleaners and detergents for Foundry Prime ro-
bots
i
This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition-
Continues on next page
10 Product manual - IRB 4600 Foundry Prime
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Overview of this manual
Continued
DescriptionRevision
The following updates have been made in this revision:
• A new SMB unit and battery is introduced, with longer battery lifetime.
• Updated the list of approved detergents, see Approved cleaners and
detergents on page 193.
A
The following updates have been made in this revision:
• Several more spare part numbers are corrected throughout the spare
part chapter.
• The list of approved cleaners and detergents is updated more fre-
quently than the manual is updated, therefore the information is re-
moved from the manual and instead referenced. See Approved
cleaners and detergents on page 193.
B
The following updates have been made in this revision:
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 384.
C
The following updates have been made in this revision:
• Illustration changes in Dimension, mounting surface and guide bushing
on page 73.
• Term "Guide sleeves" changed to "Guide bushings", see Dimension,
mounting surface and guide bushing on page 73.
• A new WARNING! is added in the section about motor replacement,
informing not to mix different motor types.
• Minor corrections.
D
The following updates have been made in this revision:
• Note added in Fitting equipment on robot.
• Foundry Prime: Seal armhouse cover with Sikaflex (several updates)
E
The following updates have been made in this revision:
• Turning disc fixture is removed from special tools for Levelmeter cal-
ibration.
• New illustrations for foundry prime air connections in manipulator
base, maintenance and repair chapter.
F
Published in release R16.2. The following updates are made in this revision:
• Corrections due to updates in terminology.
• New dimensional drawing of the turning disk added to Fitting equip-
ment on wrist and mounting flange on page 80.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 353.
• Information about grounding point added. See Robot cabling and
connection points on page 94.
• The spare part lists are removed from this manual. Valid spare part
lists are published in Product manual, spare parts - IRB 4600.
• The maintenance schedule is revised, activities not valid for IRB 4600
were incorrectly added to the schedule previously. Faulty activities
are removed.
G
Published in release R17.1. The following updates are made in this revision:
• Drying time for Mercasol added.
• Changed the tightening torque of the oil plug located on axis-1 gear-
box.
• Added information regarding tightening of protective calibration plugs
after calibration. Risk of damage on sealing washer if tightened too
hard.
H
Continues on next page
Product manual - IRB 4600 Foundry Prime 11
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Overview of this manual
Continued
DescriptionRevision
Published in release R17.2. The following updates are made in this revision:
• Information about coupled axes in Updating revolution counters on
page 360.
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Article number for the Calibration tool box, Axis Calibration is changed.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Updated the section Start of robot in cold environments on page 93.
• Updated information regarding replacement of brake release board.
• Updated information about leak proof o-ring/pressure relief valve.
• Definition of reference calibration clarified.
J
Published in release R18.1. The following updates are made in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 367.
• Added sections in General procedures on page 196.
• Updated figure of axis-6 synchronization mark.
• Updated Activities and intervals, Foundry Prime on page 110 and Oil
in axis-5 & -6 gearbox.
• New spare parts numbers for brake release boards.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calib-
ration values.
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
K
Published in release R18.2. The following updates are made in this revision:
• Updates related to mechanical stop pin.
• Changed the method for replacing the axis-1 gearbox and the base.
L
Published in release R18.2. The following updates are made in this revision:
• Updated references.
M
12 Product manual - IRB 4600 Foundry Prime
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Overview of this manual
Continued
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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
Product manual - IRB 4600 Foundry Prime 13
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Product documentation
Operating manuals
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.
14 Product manual - IRB 4600 Foundry Prime
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Product documentation
Continued
How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
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 15
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
How to read the product manual
Important information about robots with protection type
Foundry Prime
Introduction
Foundry Prime robots are specially designed to work in harsh environments. Misuse
of the robots or poor installation, cleaning, maintenance and repair can be harmful
for the functioning of the robot.
Warranty claims
Warranty claims for defect products due to misuse or failure to fulfil operational
and maintenance requirements will not be approved.
Pressurized components
Motors, balancing device and the serial measurement board cavity shall be
pressurized on Foundry Prime robots during operation and shut down. The
overpressure can be dropped when atmospheric humidity has reached the same
level as the surrounding environment.
For more information, see Pressurized components on page 48.
Cleaning
Special procedures are needed when cleaning the Foundry Prime robot. See section
Cleaning the IRB 4600 Foundry Prime on page 191.
16 Product manual - IRB 4600 Foundry Prime
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
Important information about robots with protection type Foundry Prime
1 Safety
1.1 General safety information
1.1.1 Limitation of liability
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.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Continues on next page
Product manual - IRB 4600 Foundry Prime 17
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
1 Safety
1.1.1 Limitation of liability
The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
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.
18 Product manual - IRB 4600 Foundry Prime
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
1 Safety
1.1.1 Limitation of liability
Continued
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 19
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
1 Safety
1.1.2 Protective stop and emergency stop
1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO
2
) extinguisher in the event of a fire in the
manipulator or controller.
20 Product manual - IRB 4600 Foundry Prime
3HAC040585-001 Revision: M
© Copyright 2013-2018 ABB. All rights reserved.
1 Safety
1.2.1 Fire extinguishing
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110
  • Page 111 111
  • Page 112 112
  • Page 113 113
  • Page 114 114
  • Page 115 115
  • Page 116 116
  • Page 117 117
  • Page 118 118
  • Page 119 119
  • Page 120 120
  • Page 121 121
  • Page 122 122
  • Page 123 123
  • Page 124 124
  • Page 125 125
  • Page 126 126
  • Page 127 127
  • Page 128 128
  • Page 129 129
  • Page 130 130
  • Page 131 131
  • Page 132 132
  • Page 133 133
  • Page 134 134
  • Page 135 135
  • Page 136 136
  • Page 137 137
  • Page 138 138
  • Page 139 139
  • Page 140 140
  • Page 141 141
  • Page 142 142
  • Page 143 143
  • Page 144 144
  • Page 145 145
  • Page 146 146
  • Page 147 147
  • Page 148 148
  • Page 149 149
  • Page 150 150
  • Page 151 151
  • Page 152 152
  • Page 153 153
  • Page 154 154
  • Page 155 155
  • Page 156 156
  • Page 157 157
  • Page 158 158
  • Page 159 159
  • Page 160 160
  • Page 161 161
  • Page 162 162
  • Page 163 163
  • Page 164 164
  • Page 165 165
  • Page 166 166
  • Page 167 167
  • Page 168 168
  • Page 169 169
  • Page 170 170
  • Page 171 171
  • Page 172 172
  • Page 173 173
  • Page 174 174
  • Page 175 175
  • Page 176 176
  • Page 177 177
  • Page 178 178
  • Page 179 179
  • Page 180 180
  • Page 181 181
  • Page 182 182
  • Page 183 183
  • Page 184 184
  • Page 185 185
  • Page 186 186
  • Page 187 187
  • Page 188 188
  • Page 189 189
  • Page 190 190
  • Page 191 191
  • Page 192 192
  • Page 193 193
  • Page 194 194
  • Page 195 195
  • Page 196 196
  • Page 197 197
  • Page 198 198
  • Page 199 199
  • Page 200 200
  • Page 201 201
  • Page 202 202
  • Page 203 203
  • Page 204 204
  • Page 205 205
  • Page 206 206
  • Page 207 207
  • Page 208 208
  • Page 209 209
  • Page 210 210
  • Page 211 211
  • Page 212 212
  • Page 213 213
  • Page 214 214
  • Page 215 215
  • Page 216 216
  • Page 217 217
  • Page 218 218
  • Page 219 219
  • Page 220 220
  • Page 221 221
  • Page 222 222
  • Page 223 223
  • Page 224 224
  • Page 225 225
  • Page 226 226
  • Page 227 227
  • Page 228 228
  • Page 229 229
  • Page 230 230
  • Page 231 231
  • Page 232 232
  • Page 233 233
  • Page 234 234
  • Page 235 235
  • Page 236 236
  • Page 237 237
  • Page 238 238
  • Page 239 239
  • Page 240 240
  • Page 241 241
  • Page 242 242
  • Page 243 243
  • Page 244 244
  • Page 245 245
  • Page 246 246
  • Page 247 247
  • Page 248 248
  • Page 249 249
  • Page 250 250
  • Page 251 251
  • Page 252 252
  • Page 253 253
  • Page 254 254
  • Page 255 255
  • Page 256 256
  • Page 257 257
  • Page 258 258
  • Page 259 259
  • Page 260 260
  • Page 261 261
  • Page 262 262
  • Page 263 263
  • Page 264 264
  • Page 265 265
  • Page 266 266
  • Page 267 267
  • Page 268 268
  • Page 269 269
  • Page 270 270
  • Page 271 271
  • Page 272 272
  • Page 273 273
  • Page 274 274
  • Page 275 275
  • Page 276 276
  • Page 277 277
  • Page 278 278
  • Page 279 279
  • Page 280 280
  • Page 281 281
  • Page 282 282
  • Page 283 283
  • Page 284 284
  • Page 285 285
  • Page 286 286
  • Page 287 287
  • Page 288 288
  • Page 289 289
  • Page 290 290
  • Page 291 291
  • Page 292 292
  • Page 293 293
  • Page 294 294
  • Page 295 295
  • Page 296 296
  • Page 297 297
  • Page 298 298
  • Page 299 299
  • Page 300 300
  • Page 301 301
  • Page 302 302
  • Page 303 303
  • Page 304 304
  • Page 305 305
  • Page 306 306
  • Page 307 307
  • Page 308 308
  • Page 309 309
  • Page 310 310
  • Page 311 311
  • Page 312 312
  • Page 313 313
  • Page 314 314
  • Page 315 315
  • Page 316 316
  • Page 317 317
  • Page 318 318
  • Page 319 319
  • Page 320 320
  • Page 321 321
  • Page 322 322
  • Page 323 323
  • Page 324 324
  • Page 325 325
  • Page 326 326
  • Page 327 327
  • Page 328 328
  • Page 329 329
  • Page 330 330
  • Page 331 331
  • Page 332 332
  • Page 333 333
  • Page 334 334
  • Page 335 335
  • Page 336 336
  • Page 337 337
  • Page 338 338
  • Page 339 339
  • Page 340 340
  • Page 341 341
  • Page 342 342
  • Page 343 343
  • Page 344 344
  • Page 345 345
  • Page 346 346
  • Page 347 347
  • Page 348 348
  • Page 349 349
  • Page 350 350
  • Page 351 351
  • Page 352 352
  • Page 353 353
  • Page 354 354
  • Page 355 355
  • Page 356 356
  • Page 357 357
  • Page 358 358
  • Page 359 359
  • Page 360 360
  • Page 361 361
  • Page 362 362
  • Page 363 363
  • Page 364 364
  • Page 365 365
  • Page 366 366
  • Page 367 367
  • Page 368 368
  • Page 369 369
  • Page 370 370
  • Page 371 371
  • Page 372 372
  • Page 373 373
  • Page 374 374
  • Page 375 375
  • Page 376 376
  • Page 377 377
  • Page 378 378
  • Page 379 379
  • Page 380 380
  • Page 381 381
  • Page 382 382
  • Page 383 383
  • Page 384 384
  • Page 385 385
  • Page 386 386
  • Page 387 387
  • Page 388 388
  • Page 389 389
  • Page 390 390
  • Page 391 391
  • Page 392 392
  • Page 393 393
  • Page 394 394
  • Page 395 395
  • Page 396 396
  • Page 397 397
  • Page 398 398
  • Page 399 399
  • Page 400 400
  • Page 401 401
  • Page 402 402
  • Page 403 403
  • Page 404 404
  • Page 405 405
  • Page 406 406
  • Page 407 407
  • Page 408 408

ABB IRB 4600 Foundry Prime User manual

Category
Robotics
Type
User manual

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI