ROBOT IRB 460 ABB DÀNH CHO CÁC BẠN TỰ ĐỘNG HÓA

ROBOTICS

Product manual
IRB 460


Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012


Product manual
IRB 460 - 110/2.4
IRC5
Document ID: 3HAC039842-001
Revision: P

© Copyright 2012-2018 ABB. All rights reserved.
Specifications subject to change without notice.


The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's

written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.

Original instructions.

© Copyright 2012-2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden


Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 13
How to read the product manual ...................................................................................................... 15
1

Safety

17

1.1

17
17

19
20
20
21
22
23
23
25
26
27
28
29
31
32
33
34
35
36
38
38
40

1.2

1.3

1.4

2

General safety information ..................................................................................
1.1.1 Limitation of liability .................................................................................
1.1.2 Protective stop and emergency stop ...........................................................
Safety actions ...................................................................................................
1.2.1 Fire extinguishing ....................................................................................
1.2.2 Emergency release of the robot axes ..........................................................
1.2.3 Make sure that the main power has been switched off ....................................
Safety risks ......................................................................................................
1.3.1 Safety risks during installation and service work on robots ..............................
1.3.2 Moving robots are potentially lethal ............................................................
1.3.3 First test run may cause injury or damage ....................................................
1.3.4 Work inside the working range of the robot ..................................................
1.3.5 Enabling device and hold-to-run functionality ...............................................
1.3.6 Risks associated with live electric parts .......................................................
1.3.7 The unit is sensitive to ESD .......................................................................
1.3.8 Hot parts may cause burns .......................................................................
1.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
1.3.10 Brake testing ..........................................................................................
1.3.11 Safety risks during handling of batteries ......................................................
1.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................
Safety signals and symbols .................................................................................
1.4.1 Safety signals in the manual ......................................................................
1.4.2 Safety symbols on product labels ...............................................................

Installation and commissioning

47

2.1
2.2

47
48
48
52
54
55
55
55
58
61
63
65
66
71
75
79
80
84
84
90
90
91
93
93
94
94

2.3

2.4
2.5
2.6
2.7

Introduction ......................................................................................................
Unpacking .......................................................................................................
2.2.1 Pre-installation procedure .........................................................................
2.2.2 Working range and type of motion ..............................................................
2.2.3 Risk of tipping/stability .............................................................................
On-site installation ............................................................................................
2.3.1 Lifting the robot with fork lift accessory .......................................................
2.3.1.1 Fitting the fork lift accessory ..........................................................
2.3.1.2 Lifting the robot with fork lift truck ...................................................
2.3.2 Lifting robot with roundslings ....................................................................
2.3.3 Manually releasing the brakes ...................................................................
2.3.4 Lifting the base plate ................................................................................
2.3.5 Securing the base plate ............................................................................
2.3.6 Orienting and securing the robot ................................................................
2.3.7 Fitting equipment on robot .......................................................................
2.3.8 Loads fitted to the robot, stopping time and braking distances .........................
2.3.9 Installation of signal lamp, upper arm (option) ..............................................
Installation of options .........................................................................................
2.4.1 Option 87-1 - Installing the cooling fan for axis-1 motor ..................................
Restricting the working range ..............................................................................
2.5.1 Introduction ............................................................................................
2.5.2 Mechanically restricting the working range of axis 1 ......................................
Robot in cold environments .................................................................................
2.6.1 Start of robot in cold environments ............................................................
Electrical connections ........................................................................................

2.7.1 Robot cabling and connection points ..........................................................

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Table of contents

3

Maintenance
3.1
3.2

3.3

3.4

3.5
4

97

Introduction ......................................................................................................
Maintenance schedule and expected component life ...............................................
3.2.1 Specification of maintenance intervals ........................................................

3.2.2 Maintenance schedule .............................................................................
3.2.3 Expected component life ..........................................................................
Inspection activities ...........................................................................................
3.3.1 Inspecting the oil level in axis-1 gearbox .....................................................
3.3.2 Inspecting, oil level gearbox axes 2 - 3 .......................................................
3.3.3 Inspecting, oil level gearbox axis 6 ............................................................
3.3.4 Inspecting, cable harness ........................................................................
3.3.5 Inspecting the information labels ................................................................
3.3.6 Inspecting the axis-1 mechanical stop pin ...................................................
3.3.7 Inspecting the additional mechanical stops .................................................
3.3.8 Inspection, dampers ................................................................................
3.3.9 Inspecting the signal lamp (option) .............................................................
Replacement/changing activities ..........................................................................
3.4.1 Type of lubrication in gearboxes ................................................................
3.4.2 Changing oil, axis-1 gearbox .....................................................................
3.4.3 Changing oil, gearbox axes 2 and 3 ...........................................................
3.4.4 Changing oil, gearbox axis 6 .....................................................................
3.4.5 Replacing the SMB battery ........................................................................
Cleaning activities .............................................................................................
3.5.1 Cleaning the IRB 460 ...............................................................................

97
98
98
99
101
102
102
104
107

109
111
113
115
117
119
121
121
122
126
130
132
136
136

Repair

139

4.1
4.2

139
140
140
141
143
145
146
147

147
157
164
169
173
182
182
188
209
225
233
240
256
257
268
278
285
285
294
305
313
313
323
331

4.3

4.4

4.5

4.6

Introduction ......................................................................................................
General procedures ...........................................................................................
4.2.1 Performing a leak-down test ......................................................................
4.2.2 Mounting instructions for bearings .............................................................
4.2.3 Mounting instructions for seals ..................................................................
4.2.4 Cut the paint or surface on the robot before replacing parts ............................
4.2.5 The brake release buttons may be jammed after service work .........................
Complete robot .................................................................................................
4.3.1 Replacing cable harness, lower end (axes 1-3) .............................................
4.3.2 Replacing the cable harness, upper end (incl. axis 6) .....................................
4.3.3 Replacing the SMB unit ............................................................................
4.3.4 Replacing the brake release board .............................................................
4.3.5 Replacing the base, including axis 1 gearbox ...............................................
Upper and lower arm .........................................................................................
4.4.1 Replacing the turning disk ........................................................................
4.4.2 Replacing the tilthouse unit .......................................................................
4.4.3 Replacing the upper arm ..........................................................................
4.4.4 Replacing linkage - upper link arm ..............................................................
4.4.5 Replacing linkage - lower link arm ..............................................................
4.4.6 Replacing the linkage - link .......................................................................
4.4.7 Replacing the POM sealing for the link system .............................................
4.4.8 Replacing parallel rod ..............................................................................
4.4.9 Replacing the complete lower arm system ...................................................
4.4.10 Replacing the parallel arm ........................................................................
Motors ............................................................................................................
4.5.1 Replacing motor, axis 1 ............................................................................
4.5.2 Replacing motors, axes 2 and 3 .................................................................

4.5.3 Replacing motor, axis 6 ............................................................................
Gearboxes .......................................................................................................
4.6.1 Replacing the axis 1 gearbox .....................................................................
4.6.2 Replacing the axis 2 gearbox .....................................................................
4.6.3 Replacing the axis 3 gearbox .....................................................................

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Table of contents

5

4.6.4

Replacing gearbox axis 6 .......................................................................... 338

Calibration

347

5.1

347
347
348

350
351
351
352
353
357
357
359
361
363
367
368
369

5.2
5.3
5.4

5.5
5.6
5.7
6

Decommissioning
6.1
6.2

7

8

371

Environmental information .................................................................................. 371
Scrapping of robot ............................................................................................. 373

Reference information

375

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8

375
376
378
379
382
383
384
388

Introduction ......................................................................................................
Applicable standards .........................................................................................

Unit conversion .................................................................................................
Screw joints ....................................................................................................
Weight specifications .........................................................................................
Standard tools ..................................................................................................
Special tools ....................................................................................................
Lifting accessories and lifting instructions ..............................................................

Spare parts
8.1

9

Introduction to calibration ...................................................................................
5.1.1 Introduction and calibration terminology ......................................................
5.1.2 Calibration methods .................................................................................
5.1.3 When to calibrate ...................................................................................
Synchronization marks and axis movement directions .............................................
5.2.1 Synchronization marks and synchronization position for axes .........................
5.2.2 Calibration movement directions for all axes ................................................
Updating revolution counters ...............................................................................
Calibrating with Axis Calibration method ...............................................................
5.4.1 Description of Axis Calibration ..................................................................
5.4.2 Calibration tools for Axis Calibration ...........................................................
5.4.3 Installation locations for the calibration tools ...............................................
5.4.4 Axis Calibration - Running the calibration procedure ......................................
Calibrating with Calibration Pendulum method ........................................................
Verifying the calibration ......................................................................................
Checking the synchronization position ..................................................................

389

Spare part lists and illustrations ........................................................................... 389

Circuit diagrams
9.1

391

Circuit diagrams ................................................................................................ 391

Index

393

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Overview of this manual

Overview of this manual
About this manual
This manual contains instructions for:

•

mechanical and electrical installation of the robot

•

maintenance of the robot

•

mechanical and electrical repair of the robot.

The manual also contains reference information for all procedures detailed in the
manual.
Usage
This manual should be used during:
•

installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation

•

maintenance work

•

repair work.

Who should read this manual?

This manual is intended for:
•

installation personnel

•

maintenance personnel

•

repair personnel.

Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
•

be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.

Product manual scope
The manual covers covers all variants and designs of the IRB 460. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
Chapter

Contents

Safety

Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information about how to avoid
personal injuries and damage to the product.

Installation and com- Required information about lifting and installation of the robot.
missioning
Maintenance

Step-by-step procedures that describe how to perform maintenance
of the robot. Based on a maintenance schedule that may be used
in the work of planning periodical maintenance.

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Overview of this manual
Continued

Chapter

Contents

Repair

Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.

Calibration

Calibration procedures and general information about calibration.

Decommissioning

Environmental information about the robot and its components.

Reference information Useful information when performing installation, maintenance or
repair work. Includes lists of necessary tools, additional documents,
safety standards etc.
Spare part list

Reference to the spare part list for the robot.

Circuit diagram

Reference to the circuit diagram for the robot.

References
Reference

Document ID

Product manual, spare parts - IRB 460

3HAC040628-001

Product specification - IRB 460

3HAC039611-001

Operating manual - General safety information i

3HAC031045-001

Product manual - IRC5
IRC5 with main computer DSQC 639.

3HAC021313-001

Product manual - IRC5
IRC5 with main computer DSQC1000.

3HAC047136-001

Operating manual - IRC5 with FlexPendant

3HAC050941-001

Operating manual - Service Information System

3HAC050944-001

Application manual - Electronic Position Switches

3HAC050996-001

Application manual - Additional axes and stand alone con- 3HAC051016-001
troller
Technical reference manual - Lubrication in gearboxes

3HAC042927-001

Technical reference manual - System parameters

3HAC050948-001

i

This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Revisions
Revision

Description

-

First edition.

A

This revision includes the following updates:
• Added safety section, Signal lamp (optional).
• A new block, about general illustrations, added in section How to read
the product manual on page 15.
• Illustrations improved throughout the Repair chapter.
• Method of replacing the base updated and bits holder added in section
Replacing the base, including axis 1 gearbox on page 173.
• Refitting method updated in section Replacing the turning disk.
• Re-calibration added in section Replacing the turning disk.
• Details about tools added in section Replacing the tilthouse unit on
page 188.
• Procedures for Removal and Refitting updated in section Replacing
the upper arm on page 209.

Continues on next page
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Overview of this manual
Continued

Revision

Description
•

•
•
•

•
•
•
•
•
•

Three legged bearing puller added in Required equipment sections
Replacing linkage - upper link arm on page 225 and Replacing linkage
- lower link arm on page 233.
Replacing method updated in section Replacing motors, axes 2 and
3 on page 294.
Text updated in section Replacing the axis 1 gearbox on page 313.
In previous section Replacing the axis 2 and 3 gearboxes, replacing
gearbox axis 3 has been removed and now only describes the axis 2
gearbox.
New section included Replacing the axis 3 gearbox.
Changed the weight of the robot, see Weight, robot on page 48.
Added an illustration that shows the directions of the robot stress
forces, see Loads on foundation, robot on page 49.
Added new section about how to install the signal lamp, see Installation
of signal lamp, upper arm (option) on page 80.
Added information that the working range of axis 1 also can be restricted by EPS, see Introduction on page 90.
Special tools updated.

B

This revision includes the following updates:
• Minor corrections and editorial changes made throughout the manual.
• Some general tightening torques have been changed/added, see updated values in Screw joints on page 379.
• Added steps in the instruction for replacing upper end of cabling, see
Replacing the cable harness, upper end (incl. axis 6) on page 157.
• Added Safety risks during handling of batteries on page 35.

C

This revision includes the following updates:
• The maximum allowed deviation in levelness of the base plate is
changed, see Securing the base plate on page 66.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed to
european standard C25/C30 (previously Swedish standard K25/K30),
see Securing the base plate on page 66.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of oil
in gearboxes on page 121.
• Added a new sealing structure that contains a support ring, o-ring and
radial sealing at the link, see Replacing the linkage - link on page 240
and Replacing the upper arm on page 209.
• Three o-rings are added to the equipment list and procedure in section
Replacing the axis 1 gearbox on page 313.
• A new SMB unit and battery is introduced, with longer battery lifetime.

D

This revision includes the following updates:

• A new procedure is added to the manual: Option 87-1 - Installing the
cooling fan for axis-1 motor on page 84.
• The position of the battery holder for RMU lithium battery (3-pole
battery contacts) has changed. The figures and text has been updated.

E

This revision includes the following updates:
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 373.

F

This revision includes the following updates:
• New illustrations added for lower arm and lower and upper arm joints.
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 66.
• Minor corrections.

Continues on next page
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Overview of this manual
Continued

Revision

Description

G

This revision includes the following updates:
• Splitted instruction for fork lift accessory use in two sections.
• Illustrations of SMB battery RMU improved,

H

This revision includes the following updates:
• Article number for label updated (Combined warning label "Brake release", "Brake release buttons" and "Moving robot")

J

Published in release R16.2. The following updates are made in this revision:
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 66.
• Corrections due to updates in terminology.

K

Published in release R17.1. The following updates are made in this revision:
• Added labels to the robot, one warning label (A) on the axis-6 motor,
one battery label (N) and one stock robots label (P) See Inspecting
the information labels on page 111.
• New standard calibration method is introduced (Axis Calibration). See

Calibration on page 347.

L

Published in release R17.2. The following updates are made in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Article number for the Calibration tool box, Axis Calibration is changed.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Updated the section Start of robot in cold environments on page 93.
• Updated information regarding replacement of brake release board.
• Lifting robot with roundslings updated.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.

M

Published in release R18.1. The following updates are made in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 359.
• Added section, Cut the paint or surface on the robot before replacing
parts.
• New spare part numbers brake release board.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calibration values.
• Information about myABB Business Portal added.

N

Published in release R18.2. The following updates are done in this revision:
• Added locating hole position in tool flange view.

P

Published in release R18.2. The following updates are done in this revision:
• Updated references.

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Product manual - IRB 460
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Product documentation

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
•

Safety information.

•

Installation and commissioning (descriptions of mechanical installation or
electrical connections).

•

Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).

•

Repair (descriptions of all recommended repair procedures including spare
parts).

•

Calibration.

•

Decommissioning.

•

Reference information (safety standards, unit conversions, screw joints, lists
of tools).

•

Spare parts list with corresponding figures (or references to separate spare
parts lists).

•

References to circuit diagrams.

Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
•

The purpose of the application (what it does and when it is useful).

•

What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).

•

How to install included or required hardware.

•

How to use the application.

•

Examples of how to use the application.

Continues on next page
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Product documentation
Continued

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.

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How to read the product manual

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.

8.

Action

Note/Illustration

Remove the rear attachment screws, gearbox.

Shown in the figure Location of
gearbox on page xx.

References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.

3.

Action

Note/Illustration

Fit a new sealing, axis 2 to the gearbox.

Art. no. is specified in Required
equipment on page xx.

Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.

Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.

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1 Safety
1.1.1 Limitation of liability

1 Safety
1.1 General safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:

•

Use of the robot in other ways than intended.

•

Incorrect operation or maintenance.

•

Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.

•

When instructions for operation and maintenance are not followed.

•

Non-authorized design modifications made in or around the robot.

•

Repairs carried out by in-experienced or non-qualified personnel.

•

Foreign objects.

•

Force majeure.

Nation/region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
•

The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.

•

The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.

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1 Safety
1.1.1 Limitation of liability
Continued

The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling

Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB, it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength of the robot could
be affected.

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1 Safety
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.

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1 Safety
1.2.1 Fire extinguishing

1.2 Safety actions
1.2.1 Fire extinguishing

Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the
manipulator or controller.

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Product manual - IRB 460
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1 Safety
1.2.2 Emergency release of the robot axes

1.2.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
•

Manually releasing the brakes on page 63.

The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the robot does not
increase the pressure on the trapped person, further increasing any injury.
DANGER
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.

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1 Safety
1.2.3 Make sure that the main power has been switched off

1.2.3 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. 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.

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Product manual - IRB 460
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1 Safety
1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks
1.3.1 Safety risks during installation and service work on robots
Requirements on personnel
Only persons who know the robot and are trained in the operation and handling
of the robot are allowed to maintain the robot. Persons who are under the influence
of alcohol, drugs or any other intoxicating substances are not allowed to install,
maintain, repair, or use the robot.
•

Those in charge of operations must make sure that safety instructions are
available for the installation in question.

•

Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.

•

Personnel should be trained on responding to emergency or abnormal
situations.

General risks during installation and service
The instructions in the product manual must always be followed.
Never turn the power on to the robot before it is properly fixed and bolted to its
foundation/support.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to remove the power cable to
the controller.
If the robot is installed at a height, hanging, or other than standing directly on the
floor, there may be additional risks than those for a robot standing directly on the
floor.
Energy stored in the robot for the purpose of counterbalancing certain axes may
be released if the robot, or parts thereof, are dismantled.
Never use the robot as a ladder, which means, do not climb on the controller,
motors, or other parts during service work. There is a risk of slipping because of
the high temperature of the motors and oil spills that can occur on the robot. There

is also a risk of the robot being damaged.
To avoid damaging the product, make sure that there are no loose screws, turnings,
or other parts inside the product after work has been performed.
Safety risks during operational disturbances
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
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1 Safety
1.3.1 Safety risks during installation and service work on robots
Continued

If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
Spare parts and special equipment
ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. 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.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
Personal protective equipment
Always use suitable personal protective equipment, based on the risk assessment
for the installation.
Allergenic material
See Environmental information on page 371 for specification of allergenic materials
in the product, if any.

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1 Safety
1.3.2 Moving robots are potentially lethal

1.3.2 Moving robots are potentially lethal
Description
Any moving robot is a potentially lethal machine.
When running, the robot may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located

within the working range of the robot.
Safe handling
Action

Note

1

Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is cor- tread mats, light curtains, etc.
rectly installed and connected.

2

Usually the hold-to-run function is active
only in manual full speed mode. To increase safety it is also possible to activate
hold-to-run for manual reduced speed with
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.

3

Make sure no personnel are present within
the working range of the robot before
pressing the start button.

How to use the hold-to-run function is described in section How to use the hold-torun function in the Operating manual - IRC5
with FlexPendant.

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© Copyright 2012-2018 ABB. All rights reserved.