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ABB IRB 4400 Manual

Manual is about: 3HAC 5671-1 M98A / BW OS 3.2 / Rev. 1

Summary of IRB 4400

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    Product specification 3hac 5671-1 irb 4400 m98a / bw os 3.2 / rev. 1.

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    The information in this document is subject to change without notice and should not be construed as a commitment by abb robotics products ab. Abb robotics products ab assumes no responsibility for any errors that may appear in this document. In no event shall abb robotics products ab be liable for i...

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    Product specification irb 4400 contents page product specification irb 4400 m98a/baseware os 3.2 1 1 introduction ..................................................................................................................... 3 2 description .......................................................

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    Product specification irb 4400 2 product specification irb 4400 m98a/baseware os 3.2.

  • Page 5: 1  Introduction

    Introduction product specification irb 4400 m98a/baseware os 3.2 3 1 introduction thank you for your interest in the irb 4400. This manual will give you an overview of the characteristics and performance of the robot. The irb 4400 is a 6-axis industrial robot, designed specifically for manufacturing...

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    Introduction 4 product specification irb 4400 m98a/baseware os 3.2 definition of version designation irb 4400 application / handling capacity how to use this manual the characteristics of the robot are described in chapter 2: description. The most important technical data is listed in chapter 3: tec...

  • Page 7: 2  Description

    Description product specification irb 4400 m98a/baseware os 3.2 5 2 description 2.1 structure the robot is made up of two main parts: a manipulator and a controller. Figure 1 the irb 4400 manipulator has 6 axes. Figure 2 the controller is specifically designed to control robots, which means that opt...

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    Description 6 product specification irb 4400 m98a/baseware os 3.2 2.2 safety/standards the robot complies fully with the health and safety standards specified in the eec’s machinery directives as well as ansi/ria 15.06-1992. The robot is designed with absolute safety in mind. It has a dedicated safe...

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    Description product specification irb 4400 m98a/baseware os 3.2 7 restricting the working space the movement of each of the axes can be restricted using software limits. Axes 1 and 2 can also be restricted by means of an adjustable mechanical stop. Axis 3 can be restricted using an electrical limit ...

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    Description 8 product specification irb 4400 m98a/baseware os 3.2 figure 4 window for manual operation of input and output signals. Using the joystick, the robot can be manually jogged (moved). The user determines the speed of this movement; large deflections of the joystick will move the robot quic...

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    Description product specification irb 4400 m98a/baseware os 3.2 9 using a key switch, the robot can be locked in two or three different operating modes depending on chosen mode selector: • automatic mode: running production • manual mode at reduced speed: programming and setup max. Speed: 250 mm/s (...

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    Description 10 product specification irb 4400 m98a/baseware os 3.2 2.5 programming programming the robot involves choosing instructions and arguments from lists of appropriate alternatives. Users do not need to remember the format of instructions, since they are prompted in plain english. “see and p...

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    Description product specification irb 4400 m98a/baseware os 3.2 11 program management for convenience, the programs can be named and stored in different directories. Areas of the robot’s program memory can also be used for program storage. This provides fast memory for program storage. These can the...

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    Description 12 product specification irb 4400 m98a/baseware os 3.2 2.6 automatic operation a dedicated production window with commands and information required by the operator is automatically displayed during automatic operation. The operation procedure can be customised to suit the robot installat...

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    Description product specification irb 4400 m98a/baseware os 3.2 13 the robot has several functions to provide efficient diagnostics and error reports: - it performs a self-test when power on is set. - errors are indicated by a message displayed in plain language. The message includes the reason for ...

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    Description 14 product specification irb 4400 m98a/baseware os 3.2 2.8 robot motion figure 8 working space of irb 4400/45 and /60 (dimensions in mm). 1955 2140 290 1223 irb 4400/45 and /60 irb 4400fs 0-30 o (1529) (1344) (1453) (1291).

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    Description product specification irb 4400 m98a/baseware os 3.2 15 figure 9 working space of irb 4400l/30 and l/10 (dimensions in mm). 2390 786 irb 4400l/30 2432 1453 2547 1477 905 2450 irb 4400l/10

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    Description 16 product specification irb 4400 m98a/baseware os 3.2 motion performance the quickmove tm concept means that a self-optimizing motion control is used. The robot automatically optimizes the servo parameters to achieve the best possible performance throughout the cycle - based on load pro...

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    Description product specification irb 4400 m98a/baseware os 3.2 17 the base coordinate system is attached to the base mounting surface of the robot. The tool coordinate system specifies the tool’s centre point and orientation. The user coordinate system specifies the position of a fixture or workpie...

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    Description 18 product specification irb 4400 m98a/baseware os 3.2 it is possible to select the step size for incremental jogging. Incremental jogging can be used to position the robot with high precision, since the robot moves a short distance each time the joystick is moved. During manual operatio...

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    Description product specification irb 4400 m98a/baseware os 3.2 19 the robot can work as a plc by monitoring and controlling i/o signals: - i/o instructions can be executed concurrent to the robot motion. - inputs can be connected to trap routines. (when such an input is set, the trap routine starts...

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    Description 20 product specification irb 4400 m98a/baseware os 3.2.

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 21 3 technical specification applies to standard and foundry versions unless otherwise stated. 3.1 structure weight: manipulator irb 4400/45 985 kg irb 4400/60 1040 kg irb 4400l/10 1040 kg irb 4400fs 1290 kg irb 4400l/30 106...

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    Technical specification 22 product specification irb 4400 m98a/baseware os 3.2 figure 12 view of the manipulator from the side (dimensions in mm). R 1 53 a a a - a 140 880 for 4400/45 and /60 300 730 200 1720 1380 for 4400fs and 4400l/30 920 680 890 35 310 irb 4400/45 irb 4400/60 irb 4400fs irb 4400...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 23 figure 13 view of the manipulator from above (dimensions in mm). 640 r 5 65 958 irb 4400/45 irb 4400/60 irb 4400fs irb 4400l/30

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    Technical specification 24 product specification irb 4400 m98a/baseware os 3.2 figure 14 view of the manipulator from the side and above (dimensions in mm). R 9 8.5 a - a 640 82 78 958 irb 4400l/10 a a 85 300 200 148 1720 920 128 680 890 168 1500 730 d=121 d=105 r 5 65.

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 25 3.2 safety/standards the robot conforms to the following standards: en 292-1 safety of machinery, terminology en 292-2 safety of machinery, technical specifications en 954-1 safety of machinery, safety related parts of co...

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    Technical specification 26 product specification irb 4400 m98a/baseware os 3.2 3.3 operation figure 16 the teach pendant is very easy to use since any functions provided via the function and menu keys are described in plain language. The remaining keys can perform only one function each. Display 16 ...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 27 user-defined keys (p1-p5) five user-defined keys that can be configured to set or reset an output (e.G. Open/close gripper) or to activate a system input (see chapter 3.10). 3.4 installation operating requirements protect...

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    Technical specification 28 product specification irb 4400 m98a/baseware os 3.2 language all text on the teach pendant can be displayed in several languages date and time calendar support power on sequence action taken when the power is switched on em stop sequence action taken at an emergency stop m...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 29 load diagrams load diagram for irb 4400/45 figure 18 maximum weight permitted for load mounted on the mounting flange at different positions (centre of gravity). Z = see the above diagram and the coordinate system in figu...

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    Technical specification 30 product specification irb 4400 m98a/baseware os 3.2 load diagram for irb 4400/60 figure 19 maximum weight permitted for load mounted on the mounting flange at different positions (centre of gravity). Z = see the above diagram and the coordinate system in figure 10 l = dist...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 31 load diagram for irb 4400fs and irb 4400l/30 figure 20 maximum weight permitted for load mounted on the mounting flange at different positions (centre of gravity). Z = see the above diagram and the coordinate system in fi...

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    Technical specification 32 product specification irb 4400 m98a/baseware os 3.2 load diagram for irb 4400l/10 figure 21 maximum weight permitted for load mounted on the mounting flange at different positions (centre of gravity). 200 200 z (mm) l (mm) 100 150 150 100 10 kg 6 kg 8 kg 50 85 z = see the ...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 33 mounting equipment irb 4400/45, 4400/60, 4400fs and 4400l/30 figure 22 the shaded area indicates the permitted positions (centre of gravity) for any extra equipment mounted in the holes (dimensions in mm). 200 110 106 max...

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    Technical specification 34 product specification irb 4400 m98a/baseware os 3.2 mounting equipment 4400l/10 figure 23 the shaded area indicates the permitted positions (centre of gravity) for any extra equipment mounted in the holes (dimensions in mm). 110 m8 (3x) depth of thread 14 115 m6 (2x) depth...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 35 figure 24 the mechanical interface, mounting flange (dimensions in mm). Figure 25 the mechanical interface, mounting flange (dimensions in mm). 9 15 d= 63 8 d=8 +0.015 -0 m10 (6x) 60 o 60 o 60 o 60 o 6 0 o 30 o a - a a a ...

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    Technical specification 36 product specification irb 4400 m98a/baseware os 3.2 3.5 programming the programming language - rapid - is a high-level application-oriented programming language and includes the following functionality: - hierarchial and modular structure - functions and procedures - globa...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 37 stop stops execution exit stops execution when a restart is not allowed break stops execution temporarily motion settings accset reduces the acceleration confj controls the robot configuration during joint movement confl ...

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    Technical specification 38 product specification irb 4400 m98a/baseware os 3.2 ginput reads the value of a group of digital input signals goutput reads the value of a group of digital output signals testdi tests if a digital input signal is set iodisable disables an i/o module ioenable enables an i/...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 39 tan calculates the tangent value eulerzyx calculates euler angles from an orientation orientzyx calculates the orientation from euler angles poseinv inverts a pose posemult multiplies a pose posevect multiplies a pose and...

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    Technical specification 40 product specification irb 4400 m98a/baseware os 3.2 3.6 automatic operation the following production window commands are available: - load/select the program. - start the program. - execute instruction-by-instruction (forward/backward). - reduce the velocity temporarily. -...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 41 3.8 robot motion type of motion range of movement axis 1 rotation motion +165 o to -165 o axis 2 arm motion +95 o to -70 o axis 3 arm motion +65 o to -60 o axis 4 wrist motion +200 o to -200 o axis 5 bend motion +120 o to...

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    Technical specification 42 product specification irb 4400 m98a/baseware os 3.2 type of motion range of movement axis 1 rotation motion +115 o to -115 o axis 2 arm motion +90 o to -70 o axis 3 arm motion +65 o to -60 o axis 4 wrist motion +200 o to -200 o axis 5 bend motion +120 o to -120 o axis 6 tu...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 43 type of motion range of movement axis 1 rotation motion +165 o to -165 o axis 2 arm motion +95 o to -70 o axis 3 arm motion +65 o to -60 o axis 4 wrist motion +200 o to -200 o axis 5 bend motion +120 o to -120 o axis 6 tu...

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    Technical specification 44 product specification irb 4400 m98a/baseware os 3.2 type of motion range of movement axis 1 rotation motion +165 o to -165 o axis 2 arm motion +95 o to -70 o axis 3 arm motion +65 o to -60 o axis 4 wrist motion +200 o to -200 o axis 5 bend motion +120 o to -120 o axis 6 tu...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 45 performance according to iso 9283 at rated load and 1 m/s velocity on the inclined iso test plane with all six robot axes in motion. Unidirectional pose repeatability, irb 4400/45 and /60: rp = 0.07 mm unidirectional pose...

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    Technical specification 46 product specification irb 4400 m98a/baseware os 3.2 3.9 external axes an external axis is an ac motor (irb motor type or similar) controlled via a drive unit mounted in the robot cabinet or in a separate enclosure according to figure 30. See specification of variants and o...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 47 3.10 inputs and outputs types of connection the following types of connection are available: - “screw terminals” on the i/o units. - serial interface for distributed i/o units. - air and signal connections to upper arm. F...

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    Technical specification 48 product specification irb 4400 m98a/baseware os 3.2 signal data permitted customer 24 v dc load max. 6 a digital inputs (options 201-208) 24 v dc optically-isolated rated voltage: 24 v dc logical voltage levels: “1” 15 to 35 v “0” -35 to 5 v input current at rated input vo...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 49 digital outputs 120 v ac (options 251-258) optically isolated, voltage spike protection rated voltage 120 v ac output current: max. 1a/channel, 12 a 16 channels or max. 2a/channel, 10 a 16 channels (56 a in 20 ms) min. 30...

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    Technical specification 50 product specification irb 4400 m98a/baseware os 3.2 signal connections on robot arm for connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling, one burndy utg 014 12sht connector and one burndy utg 018 23sht connector o...

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    Technical specification product specification irb 4400 m98a/baseware os 3.2 51 3.11 communication the robot has two serial channels - one rs232 and one rs422 full duplex - which can be used to communicate point to point with printers, terminals, computers and other equipment (see figure 31). Figure ...

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    Technical specification 52 product specification irb 4400 m98a/baseware os 3.2.

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    Specification of variants and options product specification irb 4400 m98a/baseware os 3.2 53 4 specification of variants and options the different variants and options for the irb 4400 are described below. The same numbers are used here as in the specification form. For software options, see product...

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    Specification of variants and options 54 product specification irb 4400 m98a/baseware os 3.2 043 hose and cables for connection of extra equipment are continuing to the wrist on the outside of the upper arm. Not available for options 025-028. Connection of signals 045 external connection the signals...

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    Specification of variants and options product specification irb 4400 m98a/baseware os 3.2 55 071- the signals are connected to 12-pole screw terminals, phoenix mstb 2.5/12-st-5.08, 074 in the controller (see figure 33). 081 1 switch, axis 1 082 2 switches, axis 1 083 3 switches, axis 1 figure 33 con...

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    Specification of variants and options 56 product specification irb 4400 m98a/baseware os 3.2 2 safety standards underwriters laboratory option 691 safety lamp is included on ul and ur robots. 695 ul listed, certificate on product level. Underwriters laboratories inc. Has tested and examined the fini...

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    Specification of variants and options product specification irb 4400 m98a/baseware os 3.2 57 figure 36 mounting plate for mounting of equipment (dimensions in mm). Cabinet type 121 standard, i.E. Without castor wheels. 122 cabinet on castor wheels. Operator’s panel the operator’s panel and teach pen...

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    Specification of variants and options 58 product specification irb 4400 m98a/baseware os 3.2 figure 37 required preparation of external panel enclosure (all dimensions in mm). Figure 38 operator’s panel mounted in a box (all dimensions in mm). 184 224 180 140 193 196 70 62 45 o external panel enclos...

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    Specification of variants and options product specification irb 4400 m98a/baseware os 3.2 59 external cable length (for external panel) 185 15 m 186 22 m 187 30 m operating mode selector 193 standard, 2 modes: manual and automatic 191* standard, 3 modes: manual, manual full speed and automatic. Disk...

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    Specification of variants and options 60 product specification irb 4400 m98a/baseware os 3.2 mains voltage the robot can be connected to a rated voltage of between 200 v and 600 v, 3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible in each connection. 151- voltage ...

  • Page 63

    Specification of variants and options product specification irb 4400 m98a/baseware os 3.2 61 144 rotary switch with door interlock and servo disconnector. This option adds a mechanical switch to the two series connected motors on contactors. The switch is operated by the same type of handle as the r...

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    Specification of variants and options 62 product specification irb 4400 m98a/baseware os 3.2 cabinet i/o modules 201-208 digital 24 vdc i/o: 16 inputs/16 outputs. 221-228 analog i/o: 4 inputs/4 outputs. 231-238 ad combi i/o: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10v). 251-258 ...

  • Page 65

    Specification of variants and options product specification irb 4400 m98a/baseware os 3.2 63 288/289 encoder interface unit for conveyor tracking conveyor tracking, or line tracking, is the function whereby the robot follows a work object which is mounted on a moving conveyor. The encoder and synchr...

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    Specification of variants and options 64 product specification irb 4400 m98a/baseware os 3.2 figure 42 dimensions for units 68a-t. Figure 43 dimension for units 67u-z, 69a-b. Communication as standard, the robot is equipped with one rs232 (sio 1) and one rs422 (sio 2) connector inside the cabinet. T...

  • Page 67

    Specification of variants and options product specification irb 4400 m98a/baseware os 3.2 65 teach pendant language: 575 english 576 swedish 577 german 578 french 579 spanish 580 portuguese 581 danish 582 italian 583 dutch 584 japanese 585 czech external axes drive unit mounted in cabinet the contro...

  • Page 68

    Specification of variants and options 66 product specification irb 4400 m98a/baseware os 3.2 24 v power supply as standard, the 24 v supply to the serial measurement board disappears almost momentarily at a power failure. To allow position control of external high speed (> 3000 rpm) motors during th...

  • Page 69

    Specification of variants and options product specification irb 4400 m98a/baseware os 3.2 67 manipulator cable, external connection 651- the cables are connected to 64-pin standard industrial connectors in accordance with 654 din 43652, located on the left-hand side of the controller and on the base...

  • Page 70

    Specification of variants and options 68 product specification irb 4400 m98a/baseware os 3.2 ram memory 402 standard, total memory 8+8 mb 403 extended memory, total 8+16 mb extra documentation product manuals g11-g13 english g21-g23 swedish g31-g33 german g41-g43 french g51-g53 spanish g61-g63 portu...

  • Page 71: 5  Accessories

    Accessories product specification irb 4400 m98a/baseware os 3.2 69 5 accessories there is a range of tools and equipment available, specially designed for the robot. Software options for robots and pc robot peripherals - track motion - tool system - motor units.

  • Page 72

    Accessories 70 product specification irb 4400 m98a/baseware os 3.2.

  • Page 73: 6  Index

    Index product specification irb 4400 m98a/baseware os 3.2 71 6 index a absolute measurement 12 accessories 69 allen bradley remote i/o 18 allen-bradley remote i/o 47, 62 analog signals 18, 49 arithmetic 36 automatic mode 9 automatic operation 12, 40 b backup absolute measurement 27 memory 39 battery...

  • Page 74

    Index 72 product specification irb 4400 m98a/baseware os 3.2 joystick 8 l language 28 lighting connection 67 teach pendant 64 load 9, 28 load diagrams 29 logical expressions 36 m mains supply 60 mains switch 60 mains voltage 59, 60 maintenance 12, 40 manipulator cable 66, 67 manual mode 9 mechanical...

  • Page 75

    Index product specification irb 4400 m98a/baseware os 3.2 73 safety lamp 7 safety lamp 54 serial communication 19, 51 service 12 service outlets 67 service position indicator 54 signal connections 50, 54 signal data 48 singular points 16 soft servo 37 space requirements 21 standards 6, 25 stationary...

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    Index 74 product specification irb 4400 m98a/baseware os 3.2.