Page 1 ROBOTICS Product manual IRB 4400...
Page 2 Trace back information: Workspace R18-1 version a9 Checked in 2018-03-22 Skribenta version 5.2.025...
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
Customer connections on upper arm ............Additional installation, Foundry Prime ..............2.7.1 Installation of IRB 4400 in a water jet application ........... 2.7.2 Commissioning (Foundry Prime) ..............Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 6 Frame and base ....................4.6.1 Replacement of balancing device ............... 4.6.2 Replacement of serial measurement unit ............. 4.6.3 Replacement of the brake release board ............Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 7 Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare Part lists Spare part lists and illustrations ................Circuit diagram Circuit diagrams ....................Index Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
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Page 9: Overview Of This Manual
• 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. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 10 Section Document references is completed with article numbers for calibration manuals. Yaskawa motors been added. Robot model IRB 4450S added. Foundry Prime (Water jet application) added. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 11 Turning disc fixture is removed from special tools for Levelmeter calib- ration. • Information about mounting guard plate at push button unit for brake release added. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 12 Updated spare part number brake release board unit (was DSQC563, is DSQC1050). • Information about myABB Business Portal added. • Added Nickel in Environmental information. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 13: Product Documentation, M2000/M2000A
A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation.
Page 14: Product Documentation, Irc5
Product documentation, IRC5 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 15 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 16: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
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 Grippers/end effectors must be designed so that they retain work pieces in the event of a power failure or a disturbance to the controller. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 19 1.1.1 Limitation of liability Continued 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 could be affected. CAUTION Ensure that a gripper is prevented from dropping a work piece, if such is used.
Page 20: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 21: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 22: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 23: Make Sure That The Main Power Has Been Switched Off
To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 24: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 25 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 26: Moving Robots Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 27: First Test Run May Cause Injury Or Damage
If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 29: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 30: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 31 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 32: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 33: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 34: Safety Risks Related To Pneumatic/Hydraulic Systems
Gravity may cause any parts or objects held by these systems to drop. 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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. xx0200000023 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 40 Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 43 Tip risk when loosening bolts 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 46 Shut off with handle 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 47: Installation And Commissioning
If the IRB 4400 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 ± 7500 N ± 9000 N Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 54 Maximum ambient temperature +55° C Maximum ambient temperature (less than 24 hrs) +70° C Maximum ambient humidity 95% at constant temperature (gaseous only) Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 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 Standard IP54 Manipulator, protection type Foundry Prime IP67, steam washable Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 56: Working Range
(no need for "rewinding" the axis). IRB 4400/60 Pos 1 Pos 0 Pos 5 Pos 6 Pos 2 Pos 3 Pos 4 (1223) 1955 xx1100000592 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 57 Position no (see Position (mm) X Position (mm) Z Angle (degrees) Angle (degrees) figure above) Axis 2 Axis 3 1700 1720 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 58 Position no (see Position (mm) X Position (mm) Z Angle (degrees) Angle (degrees) figure above) Axis 2 Axis 3 1424 2450 2401 -135 -786 1864 1265 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 59: On-Site Installation
Failure to attach the straps correctly can cause the suspended load to tilt suddenly and cause both personal injury and severe damage to the load. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 60 Manually releasing the possible to alter the positions of the arms. brakes on page Move the robot to the calibration position. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 61 Required equipment on page Lift the robot to its installation site. Make sure the slings do not rub against any sharp edges! Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 62: Manually Releasing The Brakes
The brake release unit is equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 63 See the previous figure. The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 64 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 65: Orienting And Securing The Robot
Tightening torque 350 - 400 Nm Oiled screws Level surface requirements xx0300000251 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 66 Lift the robot. Detailed in section Lifting robot with roundslings on page Move the robot to the vicinity of the installa- tion site. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 67 The screw joint must be able to withstand the stress loads defined in section Loads on foundation, robot on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 68: Fitting Equipment On The Robot
M8 (x2) Used if option 218-6 is chosen, depth of thread 9 mm M8 (x7) Depth of thread 14 mm 571 mm Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 69 M8 (x3) Depth of thread 14 mm M8 (x3) R= 92 mm, depth of thread 16 mm (If option 34-1 is chosen these holes are occu- pied) Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 70 For fastening of gripper tool flange to Robot tool flange every one of the screw holes for 6 screws, quality class 12.9 shall be used. Min. 10 mm used thread length. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 71: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 72: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 73: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 74 Drill Ø10.2 mm to a maximum depth of 45 mm and tap with M12 thread. Min. thread depth 35 mm. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 75 Fit the stop lugs firmly with attachment Specified in Required equipment on screws and washers according to the figure page Additional stops on page M12x60, tightening torque: 82 Nm, oil lubrication. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 76: Mechanically Restricting The Working Range Of Axis 2
See refer- references to the tools re- ences to these procedures quired. in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 77 View B of the lower arm Cut of the mech stop attachment Spacer Attachment screw, spacer (+nut) Damper Attachment screw, damper (+nut) Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 78 Art. no. is specified in Required equip- ment on page Attachment screws: 2 pcs/damper, M10x60. Tightening torque: 49 Nm. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 79: Electrically Restricting The Working Range Of Axis 3
Limit switch complete (3HAB 8312-1) Screw (9ADA 629-50) Attachment screw (9ADA 183-35) Retaining ring (9ABA 135-18), reducing coupling (2686 015-3), washer (2152 398-3) Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 80 (system parameter configuration) to corres- changed (Upper joint bound and Lower pond to the mechanical limitations. joint bound) are described in Technical reference manual - System parameters. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 81: Unlimited Working Range
Exploded views, in Product manual, spare parts - IRB 4400. xx0300000176 Mechanical stop axis 4 Damper axis 4 Attachment screws, mechanical stop Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 82 Remove the damper. Refit the mechanical stop to the axis 4 with 4 pcs, M8x16. Tightening torque: 24 Nm. its attachment screws. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 83: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. 0° xx0300000245 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 84: Electrical Connections
0.14 - 0.5 mm R1.CP/CS R1.CP/CS 3HAC12275-1 (protection • compression gland for cables, Standard) diameter 2 x 12 mm • key pin Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 85 • reduction hose, angled • pins for cable area of 0.13 - 0.25 R2.CP/R3.CP R2.CP/R3.CP 3HAC12326-1 • reduction hose, bottled-shaped • reduction hose, angled Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 86: Customer Connections On Upper Arm
R2.CP.A RI.CP/CS.A1 XT6.2 R2.CP.B RI.CP/CS.B1 XT6.3 R2.CP.C RI.CP/CS.C1 XT6.4 R2.CP.D RI.CP/CS.D1 XT6.5 R2.CP.E RI.CP/CS.A2 XT6.6 R2.CP.F RI.CP/CS.B2 R2.CP.G (Earth) RI.CP/CSP Earth Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 87 R1.CS/CP.B8 XT5.14 R2.CS.P R1.CS/CP.C8 XT5.15 R2.CS.R R1.CS/CP.D8 XT5.16 R2.CS.S R1.CS/CP.A9 XT5.17 R2.CS.T R1.CS/CP.B9 XT5.18 R2.CS.U R1.CS/CP.C9 XT5.19 R2.CS.V R1.CS/CP.D9 XT5.20 R2.CS.W R1.CS/CP.A10 XT5.21 R2.CS.X R1.CS/CP.B10 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 88: Additional Installation, Foundry Prime
If the pressurized air contains oil, 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. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 89 The sealings between the moving parts on the wrist must not be exposed to direct or rebounding high-pressure jet of water. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 90 A screw holes and screws B unpainted surface Protect these surfaces with Mercasol. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 91 Before running the robot in a water jet Inspection of air hoses (Foundry Prime) cleaning cell: on page 106 • perform a inspection of the pressure in motors and SMB cavity. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 92: Commissioning (Foundry Prime)
When turning off a cleaning cell we recommend that the humid air is ventilated out from the cell, to avoid that the humid air is sucked into gearboxes for example, due to the raised vacuum when cooled down. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 93: Start Of 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
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Page 95: Maintenance
If the IRB 4400 is connected to power, always make sure that the IRB 4400 is connected to protective earth before starting any maintenance work. For more information see: • Product manual - IRC5 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 96: 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 97: Maintenance Schedule
Service Information System, M2000 on page 127. The SIS used in M2004 is further described in the Operating manual - Service Information System. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 98: Maintenance Schedule
40° C. If the temperature is higher, the oil must be changed! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 99 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 100: Inspection Activities
Warning sign - Symbol of flash (5 pcs) UL/UR label Calibration label (4 pcs) Instruction plate - Lifting of robot Designation sign Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 101 Check all labels. See the figure in Location of information labels on page 100. Replace any missing or damaged labels. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 102: Inspecting Signal Lamp (Option)
Equipment 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 103 Also repair possible damages of the special Foundry Prime paint coat of the robot. Cut the paint or surface on the robot be- fore replacing parts on page 140. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 104: Inspection Of Mechanical Stop, Axis 1
The procedure below details how to inspect the mechanical stop on axis 1 WARNING If the mechanical stop has been deformed after a hard collision, it must be replaced! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 105 If the mechanical stop pin has been deformed or damaged, it must be replaced by a new one! Also check that the stop pin is properly attached. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 106: Inspection Of Air Hoses (Foundry Prime)
Pressurize by opening the cut off valve. Spray suspected leak areas with leak detec- tion spray. Note Bubbles indicate a leak. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 107 3 Maintenance 3.4.4 Inspection of air hoses (Foundry Prime) Continued Action Note When the leak is localized: correct the leak. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 108: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 109: General Maintenance Activities
It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 110 Remove the old battery pack. Fit a new battery pack with two clasps and connect the terminals to the serial measuring board. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 111: Cleaning The Irb 4400
Never point the water jet at connectors, joints, sealings, or gaskets. • Do not use compressed air to clean the robot. • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. Continues on next page...
Page 112 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
Page 113 • 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 114: Changing And Inspecting Oil
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 115: Inspection Of Oil Levels
The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located as shown in the figure below. xx0300000220 Upper oil plug, filling Lower oil plug, draining Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 116 Type and amount of oil in gearboxes on page 114. Clean and refit the oil plug. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 117 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!
Page 118: Oil Change, Gearbox Axis 4
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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 119 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!
Page 120 Type and amount of oil in gearboxes on page 114. Correct oil level is specified in section Inspection of oil levels on page 115. Clean and refit the oil plug. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 121: Oil Change, Gearbox Axis 5 And 6 (All Robot Versions)
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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 123 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!
Page 124: Oil Change, Gearbox Axis 5 And 6 (Irb 4400/L10 Only)
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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 126 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!
Page 127: Service Information System, M2000
134. parameters are to be entered from an extern- al PC, a set of software tools are available to build such an application. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 128: Description Of Service Information System (Sis)
Setting the SIS parameters on page 132. Remaining time Remaining time to next scheduled service date. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 129 Service interval exceeded When the service time has been exceeded for the selection made, an error message (Service interval exceeded!) is displayed. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 130 No data available When no data is available for the selection made, a message (No data available!) is displayed when trying to display the data. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 131: Sis System Parameters
The values can be defined by the operating organization as knowledge of the robot's working conditions are accumulated. Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. Operation time limit (service level) The number of operation hours selected as service interval.
Page 132: Setting The Sis Parameters
Select the required paramet- Available parameters are described in section SIS system ers by stepping up and parameters on page 131. down through the parameter list. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 133: Reading The Sis Output Logs
How to set the value determining when the mes- gearbox x! sage is to be shown, is detailed in section Setting the SIS parameters on page 132. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 134: Exporting The Sis Data
Operation time of gearbox axis 3 sisL10h_6 hours Gearbox time Estimated life of gearbox axis 6 sisL10h_Time_6 hours Gearbox time Operation time of gearbox axis 6 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 135: Repair
Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials. WARNING Repair activities not described in this chapter must only be carried out by ABB. Otherwise damage to the mechanics and electronics may occur. Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures.
Page 136: General Procedures
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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 137 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 138: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 139 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 140: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 141 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 142: Performing A Leak-Down Test
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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 143: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 144: Complete Robot
Connectors at the base. Connectors at the rear cover plate: R1.MP, R1.SMB, R1.CP/CS, R2.MP4-6. Brake release connectors: R2.BU, R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB, R2.FB1-3, R2.FB4-6. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 145 1, 2 and 3. Replace if damaged. Standard toolkit 3HAC17594-1 Content is defined in sec- tion Standard tools on page 291. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 146 Shown in the figure Location of cable harness, view X-X on page 145. Remove the connection boxes from the motors 1-2-3. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 147 Refit the rear cover plate. Shown in the figure Location of cable harness, axes 1-3 on page 144 Refit the covers of the connection boxes. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 148 Make sure all safety requirements are met when perform- ing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 149: Replacement Of Cable Harness, Axes 4-6
R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3.FB5, R3.FB6. Customer connections: R2.CP, R2.CS. Cable bracket inside the lower arm Cable bracket at the upper arm Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 150 See references to the tools re- references to these pro- quired. cedures in the step-by- step instructions below. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 151 Remove the cable guides and the protection Shown in the figureLocation of cable har- plate in the midle of axis 1. ness, view X-X on page 150 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 152 4-6 on page 149 any. Remove the connection box together with the cabling. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 153 Axis 5 motor Connector R3.MP5 Connector R3.FB5 Axis 6 motor Connector R3.MP6 Connector R3.FB6 Protection plate Cable strap, indoor cable strap, outdoor Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 154 4. Product manual, spare parts - IRB 4400. Reconnect all the connectors at the base. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 155 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 156: Replacement Of Complete Arm System
Grease 3HAB3537-1 Used to grease sealings and bearings. Standard toolkit 3HAC17594-1 Content is defined in section Standard tools on page 291. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 157 190. Remove the cabling down to axis 1. Detailed in section Replacement of com- plete arm system on page 156. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 158 • air pressure supply (do not turn off for Foundry Prime robots!) to the robot, before entering the robot working area. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 159 Refitting, tie rod on page 192 Refit the cabling to the upper arm. Detailed in section Refitting, cabling axes 4-6 on page 154 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 160 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 161: Upper Arm
Connectors of motors, axes 4, 5 and 6 Connection box, upper arm Calibration plate, axis 3 VK cover KM nut Screw Bearing Sealing ring Shaft end Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 162 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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 163 Remove the sealings and bearings, if dam- Shown in the figure Location of upper arm aged. on page 161 Remove the upper arm from the manipulator. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 164 Apply locking liquid on the threads of the KM Locking liquid specified in Required nut. equipment on page 162 Shown in the figure Required equipment on page 162. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 165 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 166: Replacement Of Wrist Unit
Spare part no. Art. no. Note Wrist unit 3HAB8271-1 (IRB 4400) Wrist unit 3HAB9398-1 ABB Orange (IRB 4400/L10) 3HAC050646- Graphite White Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 167 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.
Page 168 Wrist unit on robot version IRB 4400. Remove the wrist unit from the upper arm. Refitting, wrist unit IRB 4400 The procedure below details how to refit the wrist unit to robot versions IRB 4400/60 and Foundry Prime. Note 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.
Page 169 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 170: Replacement Of Arm House Unit, Axis 4
These procedures include ref- may be required. See refer- erences to the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 171 Calibration is detailed in a separate calib- ration manual enclosed with the calibra- tion tools. General calibration information is included in section Calibration on page 263. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 172 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 173: Replacement Of Mechanical Stop, Axis 4
See refer- references to the tools re- ences to these procedures quired. in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 174 Rotate axis 4 so that the damper is visible. Remove Shown in the figure Location the damper. of mechanical stop on page 173. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 175 173. Part no. is specified in quired equipment on page 173. 4 pcs, M8x16. Tightening torque: 24 Nm. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 176: Replacement Of Signal Cabling, Upper Arm (Option 042)
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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 177 Remove dirt and grease from the surface first! Move axis 4 to its calibration position (0°). Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 178 Complete the rotation. Note! Do not tighten the rear cable holder, leave it open! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 179 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 180: Measuring The Play, Axis 5
Move the robot to calibration position and turn the axis 4 90°. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 181 B: 140 mm • C: 85 mm • F: 40 N Remove the load and set the dial indicator to zero. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 183: Measuring The Play, Axis 6
Fit the measuring tool, play to the turning Art. no. is specified in Required equipment disk. on page 183. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 184 B: 100 mm • C: 150 mm • F: 40 N Remove the load and set the dial indicat- or to zero. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 185 (B) from the center of axis 6 is, for robot version: • IRB 4400: 0.15 mm • IRB 4400/L10: 0.2 mm Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 186: Lower Arm
A more detailed view of the component and its position may be found in chapter Exploded views, in Product manual, spare parts - IRB 4400. xx0300000141 Lower arm Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 187 • air pressure supply (do not turn off for Foundry Prime robots!) to the robot, before entering the robot working area. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 188 Lift the lower arm and lower it into mounting position. Make sure both V-rings stay seated properly! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 189 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 190: Replacement Of Tie Rod
Sealing, outside Spherical roller bearing Sealing, inside Required equipment Equipment, etc. Spare part no. Art. no. Note Washer 3HAB3704-1 Replace if damaged. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 191 Lock the upper arm in a horizontal position with help of a crane or similar. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 192 Shown in the figure Location locking liquid. of tie rod on page 190 Locking liquid is specified in Required equipment on page 190 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 193 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 194: Replacement Of Parallel Arm / Replacement Of Bearing
Exploded views, in Product manual, spare parts - IRB 4400. xx0300000128 Parallel arm Attachment screw Washer V-ring on parallel arm Bearing Sealing Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 195 All lifting accessories used must be sized accordingly! Remove the tie rod. Detailed in Replacement of tie rod on page 190. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 196 Fit the new V-ring to the parallel arm. Part no. is specified in Required equip- ment on page 195 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 197 These are further detailed in the section First test run may cause injury or dam- age on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 198: Frame And Base
Exploded views, in Product manual, spare parts - IRB 4400. xx0300000100 Balancing device Bracket Attachment screws, bracket (M12x50) Press out hole Front screws Fork End part of shaft Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 199 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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 200 Move the manipulator to the calibration pos- ition, as shown in the figure to the right. xx0300000088 • A: Approximately 2º Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 201 Dimension specified in Required equip- ment on page 199! Check that the piston is unloaded by moving it manually. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 202 If the balancing device is to be replaced with a new device, the bracket on the right side must be removed and fitted to the new device. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 203 2 pcs. MC6S M10x12 8.8 fzb. out holes in both the brackets. Shown in the figure Location of balan- cing device on page 198 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 204 203 of the balancing device. Make sure that the fork does not cover the lubrication holes of the shaft! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 205 Make sure all safety requirements are met when perform- ing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 206: Replacement Of Serial Measurement Unit
It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 207 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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 208 R2.G connector to release the page 206. lock while pulling the connector upwards. Removal of the battery cable connector: xx1700000993 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 209 Calibration is detailed in a sep- arate calibration manual en- closed with the calibration tools. General calibration information is included in section Calibra- tion on page 263. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 210: Replacement Of The Brake Release Board
Brake release unit with 3HAC065019- DSQC1050 harness and bracket Standard toolkit 3HAC17594- Content is defined in section Standard tools on page 291. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 211 Remove the connectors X8, X9 and X10 from the brake release board. xx1700000978 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 212 Refit the rear cover plate to the base of the robot. Shown in the figure Location of the brake release board on page 210. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 213 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 214: Replacement Of Mechanical Stop Pin, Axis 1
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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 215 214. Refit the new mechanical stop with the set screw. Part no. is specified in quired equipment on page 214. M10x12 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 216: Motors
(IRB 4400) Includes motor pinion. 3HAC021724-001 Color: ABB Orange Yaskawa Includes pinion 3HAC021724-003 Color: Graphite White Yaskawa Includes pinion O-ring, motor 21520431-11 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 217 To avoid this, move the robot into normal calibration position or move axis 1 to get the lowest location of the center of gravity for the upper arm. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 218 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 219 There should be a big backlash between the motor pinion and the gear. xx0300000155 A: Lower screw B: Upper screw C: Pushing direction Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 220 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 221: Replacement Of Motor, Axis 2
3HAC021725-001 Color: ABB Orange Yaskawa Includes pinion 3HAC021725-003 Color: Graphite White Yaskawa Includes pinion O-ring 21520431-11 Flange sealing 12340011-11 Loctite 574 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 222 Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Remove the cover of the connection box. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 223 Release the brake of the motor by connecting Connect to connector R3.MP2 the 24 VDC power supply. • +24V: pin 7 • 0V: pin 8 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 224 Calibration is detailed in a separate cal- ibration manual enclosed with the calib- ration tools. General calibration information is in- cluded in section Calibration on page 263. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 225 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 226: Replacement Of Motor, Axis 3
3HAC021725-001 Color: ABB Orange Yaskawa Includes pinion 3HAC021725-003 Color: Graphite White Yaskawa Includes pinion O-ring 21520431-11 Flange sealing 12340011-116 Loctite 574 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 227 Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Remove the cover from the connection box. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 228 Release the brake of the motor by connecting Connect to connectorR3.MP3 the 24 VDC power supply. • +24V: pin 7 • 0V: pin 8 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 229 Calibration is detailed in a separate calib- ration manual enclosed with the calibration tools. General calibration information is included in section Calibration on page 263. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 230 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 231: Adjustment Of Motors, Axes
Fit the measuring tool to the motor axis. Art. no. is specified in Required equip- ment on page 231. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 232 Continue refitting the motor. Refitting, motor axis 1 on page 218 Refitting, motor axis 2 on page 223 Refitting motor axis 3 on page 228 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 233: Removal Of Motor, Axes 4, 5 And 6 .............................................................. 4.7.6 Refitting Of Motor, Axis 4
Circuit diagram See chapter Circuit diagram on page 297. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 234 The motor must be mounted back at the same position. Remove the attachment screws and washers, motor. Shown in the figure Location of motors on page 233. Remove the motor. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 235 Motor unit, axis 4 3HAC10603-1 Elmo (IRB 4400) Includes pinion. 3HAC021726-001 Color: ABB Orange Yaskawa Includes pinion 3HAC021726-003 Color: Graphite White Yaskawa Includes pinion Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 236 • air pressure supply (do not turn off for Foundry Prime robots!) to the robot, before entering the robot working area. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 237 Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is in- cluded in section Calibration on page 263. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 238 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 239: Refitting Of Motor, Axis 5
Exploded views, in Product manual, spare parts - IRB 4400. xx0300000164 Motor unit, axis 4 Motor unit, axis 5 Motor unit, axis 6 Attachment screws and washers, motor Connection box Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 240 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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 241 Refit the motor with its attachment screws and Shown in the figure Location of washers, motor. motor on page 239. 4 pcs, M6x25. Tightening torque: 15 Nm. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 242 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 243: Refitting Of Motor, Axis 6
Note Motor unit, axis 6 3HAC10604-1 Elmo (IRB 4400) Includes pinion. Motor unit, axis 6 3HAC021728-001 Yaskawa (IRB 4400) Includes pinion Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 244 • air pressure supply (do not turn off for Foundry Prime robots!) to the robot, before entering the robot working area. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 245 Shown in the figure Location of motor on page 243. Make sure the gaskets are seated properly! Reconnect all the connectors. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 246 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 247: Gearboxes
(IRB 4400) Sealing 3HAC5479-2 Replace if damaged! Standard toolkit 3HAC17594- Content is defined in section Standard tools on page 291. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 248 206. Remove the tie rod. Detailed in section Replacement of tie rod on page 190. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 249 Shown in the figure Refitting, complete arm system on page 158. Move the lifting straps to the base and unload its weight. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 250 All lifting accessories used must be sized accordingly! CAUTION The robot arm system weighs 245 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 251 Refit the robot to the foundation. Refit the complete arm system. Detailed in section Replacement of complete arm system on page 156 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 252 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 253: Adjusting Play On Axis 4, Intermediate Gear
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 140. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 254 Apply flange sealing to the cover and refit Art. no. is specified in Required it with its attachment screws and washers. equipment on page 253. 10 pcs: M8x40. Tightening torque: 24 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 255: Additional Repair Routines For Foundry Prime
• A: Sikaflex • B: Gasket Cut the projecting part of the gas- ket with a knife. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 256 • A: Sikaflex Apply Sikaflex 521FC underneath the cover attachment screw heads. xx0600003113 • A: Sikaflex Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 257 2 and 3 (not used earth connection. Cable box, motor unit axes 4-6 Additional r • A: Air connection on motor cable box axis 4-6 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 258 Mercasol on both side of the ear and both side of the washers. xx0600003123 • A: Mercasol Replacement of air hose (Required equipment) xx0600003342 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 259 260. 425 mm From the Y-plug connector at axis 3 motors to the straight fitting in the motor cover axis 3. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 260 The hose is drawn through a drilled hole in the rubber sealing and firmly tightened with a straight fitting. Additional r Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 261 Additional r The hose continue through the lower arm and is connected to a Y-plug connector at the upper arm housing. xx0600003120 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 262 T-plug connector to the cable boxes xx0600003121 xx0600003122 From the Y-plug connector for the balancing cylinder to the elbow plug in the back of the balancing cylinder. xx0600003344 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 263: Calibration
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 264: Calibration Methods
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). Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q ©...
Page 265 Levelmeter calibration - alternative method Levelmeter calibration is referred to as the alternative method for calibration of ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.
Page 266: Synchronization Marks And Synchronization Position For Axes
2, 3, 4 and 5 are marked using punch mark tools. xx0300000209 Punch, axis 2, 3HAB 1521-1 Punch, axis 3, 3HAB 1522-1 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 267 5.3 Synchronization marks and synchronization position for axes Continued Punch, axis 4, 3HAB 1523-1 (there are two different versions of the marks, as shown in the figure) Punch, axis 5, 3HAB 1524-1 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 268: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 269: Updating Revolution Counters
Make sure the axes are positioned according to the correct calibration values, not only according to the synchronization marks. The correct values are found on a Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 270 The Calibration window appears. If there is more than one unit connected to the manipulator, they will be listed in the window. xx0100000201 Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 271 Check the synchronization position very carefully after each update. How to perform the check is detailed in section Checking the synchron- ization position on page 274. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 272 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 273 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 274. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 274: Checking The Synchronization Position
If they do not, update the revolu- synchronization position for axes on tion counters. page 266 Updating revolution counters on page 269. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 275 If they do not, up- ization position for axes on page 266 date the revolution counters. Updating revolution counters on page 269. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 276: Additional Calibration Instruction, Irb 4400
Before updating the revolution counters (coarse calibration) on IRB 4400, the stainless steel metal ring on axis 4 need to be removed. Illustration xx0600003124 Upper arm Stainless steel ring Hose clamp Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 277: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 278 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 279: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 280 Double-check the number of coils cut and make sure all the tension in the springs is removed. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 281: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 282 This page is intentionally left blank...
Page 283: Reference Information
7.1 Introduction 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 284: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 285 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 286: Unit Conversion
1 kg 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 287: 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 288 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 289 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 290: 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 291: Standard Tools
Box spanner set Screwdriver Torx socket no:20, 25, 30 Extension bar 100 mm Puller bar KM nut (KM10, KM17) Lifting hoist Cutting pliers Torque wrench 10-470 Nm Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 292: Special Tools
The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method. Description Art. no. Note Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 293: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 294 This page is intentionally left blank...
Page 295: 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 296 This page is intentionally left blank...
Page 297: Circuit Diagram
Circuit diagram - IRB 6400RF 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 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 298 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 299: Index
277 disposal, 277 mechanical stop axis 2, 76 MoveAbsJ instruction, 274 danger levels, 39 TPU, 274 detergents approved, 113 requirements, 113 nation specific regulations, 17 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 300 26 jogging to calibration position, 275 release robot axes, 22 MoveAbsJ instruction, 274 signals, 39 updating revolution counters, 270 signals in manual, 39 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 301 196, 200, 203, 248, 250, 290 working range restricting axis 2, 76 validity and responsibility, 17 restricting axis 3, 79 velocity adjusting, 93 zero position checking, 274 weight, 52 Product manual - IRB 4400 3HAC022032-001 Revision: Q © Copyright 2004-2018 ABB. All rights reserved.
Page 304 Robotics and Motion No. 4528 Kangxin Highway 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 2004-2018 ABB. All rights reserved.

This manual is also suitable for:

Irb 4400/l10

ABB IRB 4400/60 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Part Lists

9 Circuit Diagram

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