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IRB 4400 - L10
ABB IRB 4400 - L10 Manuals
Manuals and User Guides for ABB IRB 4400 - L10. We have
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ABB IRB 4400 - L10 manuals available for free PDF download: Product Manual, Product Specification
ABB IRB 4400 - L10 Product Manual (322 pages)
Articulated robot
Brand:
ABB
| Category:
Robotics
| Size: 13.34 MB
Table of Contents
Table of Contents
5
Overview
9
Product Documentation, M2000/M2000A
11
Product Documentation, M2004
12
How to Read the Product Manual
14
1 Safety
15
Introduction
15
General Safety Information
16
Safety in the Robot System
16
Safety Risks
17
Safety Risks During Installation and Service Work on Robot
17
Safety Risks Related to Tools/Workpieces
19
Safety Risks Related to Pneumatic/Hydraulic Systems
20
Safety Risks During Operational Disturbances
21
Risks Associated with Live Electric Parts
22
Safety Actions
24
Safety Fence Dimensions
24
Fire Extinguishing
25
Emergency Release of the Robot's Arm
26
Brake Testing
27
Risk of Disabling Function "Reduced Speed 250 MM/S
28
Safe Use of the Flexpendant
29
Work Inside the Manipulator's Working Range
30
Translate the Information on Safety and Information Labels
31
Safety Related Instructions
32
Safety Signals, General
32
DANGER - Moving Manipulators Are Potentially Lethal
34
DANGER - First Test Run May Cause Injury or Damage
35
WARNING - the Unit Is Sensitive to ESD
36
WARNING - Safety Risks During Work with Gearbox Oil
38
2 Installation and Commissioning
39
Introduction
39
Unpacking
40
Pre-Installation Procedure
40
Working Range, IRB 4400/45 and /60
44
Working Range, IRB 4400/L30
45
Working Range, IRB 4400/L10
46
Working Range, IRB 4400/S
47
Working Range, IRB 4450S
48
Risk of Tipping/Stability - IRB 4450S
49
On-Site Installation
50
Lifting Robot with Round Slings
50
Manually Releasing the Brakes
56
Orienting and Securing the Robot
59
Fitting Equipment on Robot
62
Loads
66
Restricting the Working Range
67
Introduction
67
Mechanically Restricting the Working Range of Axis 1
68
Mechanically Restricting the Working Range of Axis 2
71
Electrically Restricting the Working Range of Axis 3
75
Unlimited Working Range
77
Electrical Connections
79
Customer Connection on Robot
79
Customer Connections on Upper Arm
81
Additional Installation (Foundry Prime)
83
Installation of IRB4400 in a Water Jet Application
83
Commissioning (Foundry Prime)
86
Making Robot Ready for Operation (Cleanroom)
87
Additional Installation Procedure
87
3 Maintenance
89
Introduction
89
Maintenance Schedule
90
Specification of Maintenance Intervals
90
Maintenance Schedule
91
General Maintenance Activities
93
Inspection of Mechanical Stop, Axis 1
93
Inspection of Air Hoses (Foundry Prime)
95
Replacement of Battery Pack, Measuring System
96
Cleaning of Manipulator
98
Change and Checking of Oil
99
Oil in Gearbox Unit, Axis 1-2-3
99
Inspection of Oil Levels
100
Oil Change, Gearbox Axis 4
104
Oil Change, Gearbox Axis 5 and 6 (All Robot Versions Except IRB 4400/L10)
107
Oil Change, Gearbox Axis 5 and 6 (IRB 4400/L10 Only)
110
4 Repair
113
Introduction
113
General Procedures
114
Performing a Leak-Down Test
114
Mounting Instructions for Bearings
115
Mounting Instructions for Seals
116
Complete Robot
118
Replacement of Cable Harness, Axes 1-3
118
Replacement of Cable Harness, Axes 4-6
123
Replacement of Complete Arm System
130
Upper Arm
135
Replacement of Complete Upper Arm
135
Replacement of Wrist Unit
140
Replacement of Arm House Unit, Axis 4
146
Replacement of Mechanical Stop, Axis 4
149
Replacement of Signal Cabling, Upper Arm (Option 042)
152
Measuring the Play, Axis 5
156
Measuring the Play, Axis 6
159
Lower Arm
162
Replacement of Lower Arm
162
Replacement of Tie Rod
166
Replacement of Parallel Arm / Replacement of Bearing
170
Frame and Base
174
Replacement of Balancing Device
174
Replacement of Serial Measurement Unit
182
Replacement of Pushbutton Unit for Brake Release
185
Replacement of Mechanical Stop Pin, Axis 1
188
Motors
190
Replacement of Motor, Axis 1
190
Replacement of Motor, Axis 2
196
Replacement of Motor, Axis 3
200
Adjustment of Motors, Axes 1-3
204
Removal of Motor, Axes 4, 5 and 6
206
Refitting of Motor, Axis 4
209
Refitting of Motor, Axis 5
212
Refitting of Motor, Axis 6
216
Gearboxes
220
Replacement of Gearbox Unit, Axes 1-2-3
220
Adjusting Play on Axis 4, Intermediate Gear
226
Additional Repair Routines (Foundry Prime)
228
Introduction
228
Repair Routines
228
5 Calibration Information
237
Introduction
237
Calibration Methods
238
Calibration Scales and Correct Axis Position
240
Calibration Movement Directions for All Axes
242
Updating Revolution Counters
243
Checking the Calibration Position
247
Additional Calibration Instruction, IRB4400
249
Overview
251
Product Documentation, M2000/M2000A
253
Product Documentation, M2004
254
6 Reference Information
257
Introduction
257
Applicable Safety Standards
258
Unit Conversion
259
Screw Joints
260
Weight Specifications
263
Document References
264
Standard Toolkit
266
Special Tools
268
Lifting Equipment and Lifting Instructions
282
7 Part List
283
Introduction
283
Manipulator
284
Upper Arm Part, Axes 4-6
288
Serial Measurement Unit
291
Position Switch, Axis 1
292
8 Foldouts
295
Introduction
295
9 Circuit Diagram
297
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ABB IRB 4400 - L10 Product Manual (304 pages)
Brand:
ABB
| Category:
Robotics
| Size: 5.41 MB
Table of Contents
Table of Contents
5
Overview of this Manual
9
Product Documentation, M2000/M2000A
13
Product Documentation, IRC5
14
How to Read the Product Manual
16
1 Safety
17
General Safety Information
17
Limitation of Liability
17
Protective Stop and Emergency Stop
20
Safety Actions
21
Fire Extinguishing
21
Emergency Release of the Robot Axes
22
Make Sure that the Main Power Has Been Switched off
23
Safety Risks
24
Safety Risks During Installation and Service Work on Robots
24
Moving Robots Are Potentially Lethal
26
First Test Run May Cause Injury or Damage
27
Work Inside the Working Range of the Robot
28
Enabling Device and Hold-To-Run Functionality
29
Risks Associated with Live Electric Parts
30
The Unit Is Sensitive to ESD
32
Hot Parts May Cause Burns
33
Safety Risks Related to Pneumatic/Hydraulic Systems
34
Brake Testing
35
Safety Risks During Handling of Batteries
36
Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
37
Safety Signals and Symbols
39
Safety Signals in the Manual
39
Safety Symbols on Product Labels
41
2 Installation and Commissioning
47
Introduction
47
Installation and Operational Requirements for Foundry Prime Robots
48
Unpacking
52
Pre-Installation Procedure
52
Working Range
56
On-Site Installation
59
Lifting Robot with Roundslings
59
Manually Releasing the Brakes
62
Orienting and Securing the Robot
65
Fitting Equipment on the Robot
68
Mounting Equipment
68
Loads Fitted to the Robot, Stopping Time and Braking Distances
71
Restricting the Working Range
72
Axes with Restricted Working Range
72
Mechanically Restricting the Working Range of Axis 1
73
Mechanically Restricting the Working Range of Axis 2
76
Electrically Restricting the Working Range of Axis 3
79
Unlimited Working Range
81
Risk of Tipping/Stability
83
Electrical Connections
84
Customer Connection on Robot
84
Customer Connections on Upper Arm
86
Additional Installation, Foundry Prime
88
Installation of IRB 4400 in a Water Jet Application
88
Commissioning (Foundry Prime)
92
Start of Robot in Cold Environments
93
3 Maintenance
95
Introduction
95
Introduction for Foundry Prime Robots
96
Maintenance Schedule
97
Specification of Maintenance Intervals
97
Maintenance Schedule
98
Inspection Activities
100
Inspecting Information Labels
100
Inspecting Signal Lamp (Option)
102
Inspection of Mechanical Stop, Axis 1
104
Inspection of Air Hoses (Foundry Prime)
106
Inspection of Surface Treatment (Foundry Prime)
108
General Maintenance Activities
109
Replacing the SMB Battery
109
Cleaning the IRB 4400
111
Changing and Inspecting Oil
114
Type of Lubrication in Gearboxes
114
Inspection of Oil Levels
115
Oil Change, Gearbox Axis 4
118
Oil Change, Gearbox Axis 5 and 6 (All Robot Versions)
121
Oil Change, Gearbox Axis 5 and 6 (IRB 4400/L10 Only)
124
Service Information System, M2000
127
Using the SIS System
127
Description of Service Information System (SIS)
128
SIS System Parameters
131
Setting the SIS Parameters
132
Reading the SIS Output Logs
133
Exporting the SIS Data
134
4 Repair
135
Introduction
135
General Procedures
136
Mounting Instructions for Bearings
136
Mounting Instructions for Seals
138
Cut the Paint or Surface on the Robot before Replacing Parts
140
Performing a Leak-Down Test
142
The Brake Release Buttons May be Jammed after Service Work
143
Complete Robot
144
Replacement of Cable Harness, Axes 1-3
144
Replacement of Cable Harness, Axes 4-6
149
Replacement of Complete Arm System
156
Upper Arm
161
Replacement of Complete Upper Arm
161
Replacement of Wrist Unit
166
Replacement of Arm House Unit, Axis 4
170
Replacement of Mechanical Stop, Axis 4
173
Replacement of Signal Cabling, Upper Arm (Option 042)
176
Measuring the Play, Axis 5
180
Measuring the Play, Axis 6
183
Lower Arm
186
Replacement of Lower Arm
186
Replacement of Tie Rod
190
Replacement of Parallel Arm / Replacement of Bearing
194
Frame and Base
198
Replacement of Balancing Device
198
Replacement of Serial Measurement Unit
206
Replacement of the Brake Release Board
210
Replacement of Mechanical Stop Pin, Axis 1
214
Motors
216
Replacement of Motor, Axis 1
216
Replacement of Motor, Axis 2
221
Replacement of Motor, Axis 3
226
Adjustment of Motors, Axes
231
Removal of Motor, Axes 4, 5 and 6 .............................................................. 4.7.6 Refitting of Motor, Axis 4
233
Refitting of Motor, Axis 5
239
Refitting of Motor, Axis 6
243
Gearboxes
247
Replacement of Gearbox Unit, Axes 1-2-3
247
Adjusting Play on Axis 4, Intermediate Gear
253
Additional Repair Routines for Foundry Prime
255
Repair Routines
255
5 Calibration
263
When to Calibrate
263
Calibration Methods
264
Synchronization Marks and Synchronization Position for Axes
266
Calibration Movement Directions for All Axes
268
Updating Revolution Counters
269
Checking the Synchronization Position
274
Additional Calibration Instruction, IRB 4400
276
6 Decommissioning
277
Environmental Information
277
Decommissioning of Balancing Device
279
Scrapping of Robot
281
7 Reference Information
283
Introduction
283
Applicable Standards
284
Unit Conversion
286
Screw Joints
287
Weight Specifications
290
Standard Tools
291
Special Tools
292
Lifting Accessories and Lifting Instructions
293
8 Spare Part Lists
295
Spare Part Lists and Illustrations
295
9 Circuit Diagram
297
Circuit Diagrams
297
Index
299
ABB IRB 4400 - L10 Product Specification (68 pages)
Articulated robot
Brand:
ABB
| Category:
Robotics
| Size: 1.22 MB
Table of Contents
Table of Contents
5
1 Description
9
Structure
9
Introduction
9
Different Robot Versions
11
Definition of Version Designation
11
Safety/Standards
18
Standards
18
Safety
19
Installation
21
Introduction
21
Operating Requirements
22
Mounting the Manipulator
23
Calibration and References
27
Fine Calibration
27
Absolute Accuracy Calibration
28
Load Diagrams
30
Introduction
30
Diagrams
31
Maximum Load and Moment of Inertia for Full Axis 5 Movement
35
Wrist Torque
36
Mounting Equipment
37
Introduction
37
Robot Tool Flange
40
Maintenance and Troubleshooting
41
Introduction
41
Robot Motion
42
Introduction
42
Performance According to ISO 9283
50
Velocity
51
Stopping Distance/Time
52
Signals
53
2 Specification of Variants and Options
55
Introduction
55
General
55
Manipulator
55
Floor Cables
62
Documentation
62
3 Accessories
63
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