ABB IRB 6650S-90/3.9, IRC5 Compact, M2000, M2000A Product Manual

ROBOTICS

Product manual

IRB 6650S

Trace back information:

Workspace R18-2 version a18

Checked in 2018-11-20

Skribenta version 5.3.012

Product manual

IRB 6650S - 200/3.0

IRB 6650S - 125/3.5

IRB 6650S - 90/3.9

M2000, M2000A, IRC5

Document ID: 3HAC020993-001

Revision: Z

© Copyright 2004-2018 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.



ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents


Overview of this manual ...................................................................................................................

Product documentation, M2000/M2000A .........................................................................................

Product documentation, IRC5 ..........................................................................................................

How to read the product manual ......................................................................................................

9

16

17

19

1 Safety

1.1

General safety information ..................................................................................

1.1.1

Limitation of liability .................................................................................

1.1.2

Protective stop and emergency stop ...........................................................

1.2

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 ....................................

1.3

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) .......................

1.4

Safety signals and symbols .................................................................................

1.4.1

Safety signals in the manual ......................................................................

1.4.2

Safety symbols on product labels ...............................................................

21

32

33

35

36

27

29

30

31

24

25

26

27

21

21

23

24

37

38

39

40

42

42

44

2 Installation and commissioning 51

2.1

Introduction ......................................................................................................

2.2

Unpacking .......................................................................................................

2.2.1

Pre-installation procedure .........................................................................

2.2.2

Working range and type of motion ..............................................................

2.2.3

Risk of tipping/stability .............................................................................

2.3

On-site installation ............................................................................................

2.3.1

Lifting robot with fork lift ...........................................................................

2.3.2

Lifting robot with roundslings ....................................................................

2.3.3

Lifting robot with lifting slings ....................................................................

2.3.4

Manually releasing the brakes ...................................................................

2.3.5

Lifting the base plate ................................................................................

2.3.6

Securing the base plate ............................................................................

2.3.7

Orienting and securing the robot ................................................................

2.3.8

Fitting equipment on robot .......................................................................

2.3.9

Signal lamp (option) .................................................................................

2.3.10 Installation of base spacers (option) ...........................................................

2.3.11 Installation of cooling fan for motors (option) ................................................

2.3.12 Installation of Foundry Plus Cable guard (option no. 908-1) .............................

2.3.13 Loads fitted to the robot, stopping time and braking distances .........................

2.4

Restricting the working range ..............................................................................

2.4.1

Axes with restricted working range .............................................................

2.4.2

Mechanically restricting the working range of axis 1 ......................................

2.4.3

Extended working range, axis 1 (option 561-1) .............................................

2.4.4


2.4.5


78

81

87

88

68

70

72

73

60

61

61

66

51

52

52

56

98

99

101

102

104

90

96

97

98

Product manual - IRB 6650S

3HAC020993-001 Revision: Z

5



2.4.6

Installation of position switches (option) ......................................................

2.5

Electrical connections ........................................................................................

2.5.1

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

2.6

Start of robot in cold environments ......................................................................

107

119

119

124

3 Maintenance 125

3.1

Introduction ......................................................................................................

3.2

Maintenance schedule and expected component life ...............................................

3.2.1

Specification of maintenance intervals ........................................................

3.2.2

Maintenance schedule .............................................................................

3.2.3

Expected component life .........................................................................

3.3

Inspection activities ...........................................................................................

3.3.1

Inspecting the motor seal .........................................................................

3.3.2

Inspecting the oil level in axis-1 gearbox .....................................................

3.3.3


3.3.4


3.3.5


3.3.6


3.3.7


3.3.8

Inspecting the balancing device .................................................................

3.3.9

Inspecting the cable harness .....................................................................

3.3.10 Inspecting the information labels ................................................................

3.3.11 Inspecting the axis-1 mechanical stop pin ...................................................

3.3.12 Inspecting the additional mechanical stops .................................................

3.3.13 Inspecting the damper on axes 2-5 .............................................................

3.3.14 Inspection, position switch axes 1, 2 and 3 ...................................................

3.3.15 Inspecting, signal lamp ............................................................................

3.4

Replacement/changing activities ..........................................................................

3.4.1

Type of lubrication in gearboxes ................................................................

3.4.2

Changing oil, axis-1 gearbox .....................................................................

3.4.3


3.4.4


3.4.5


3.4.6


3.4.7


3.4.8

Replacing the SMB battery ........................................................................

3.5

Lubrication activities ..........................................................................................

3.5.1

Lubrication of spherical roller bearing, balancing device .................................

3.6

Cleaning activities .............................................................................................

3.6.1

Cleaning the IRB 6650S ............................................................................

3.7

Service Information System, M2000 ......................................................................

3.7.1

Using the SIS system ...............................................................................

3.7.2

Description of Service Information System (SIS) ...........................................

3.7.3

SIS system parameters ............................................................................

3.7.4

Setting the SIS parameters .......................................................................

3.7.5

Reading the SIS output logs ......................................................................

3.7.6

Exporting the SIS data .............................................................................

177

180

183

186

189

192

196

196

161

163

166

168

170

172

172

174

199

199

202

202

203

206

207

208

209

136

138

141

143

145

150

155

159

125

126

126

127

131

132

132

134

4 Repair 211

4.1

Introduction ......................................................................................................

4.2

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 .........................

4.3

Complete robot .................................................................................................

4.3.1

Replacing cable harness, axes 1-6 .............................................................

4.3.2

Replacement of cable harness, axes 1-4 .....................................................

211

212

212

213

215

217

218

219

219

232

6 Product manual - IRB 6650S




4.3.3

Replacement of cable harness, axes 5-6 ......................................................

4.3.4

Replacement of cabling, axis 5 motor ..........................................................

4.3.5

Replacement of complete arm system .........................................................

4.4

Upper and lower arm .........................................................................................

4.4.1

Replacing the turning disk ........................................................................

4.4.2

Replacement of complete wrist unit ............................................................

4.4.3

Replacement of upper arm ........................................................................

4.4.4

Replacement of complete lower arm ...........................................................

4.4.5

Replacement of lower arm shaft .................................................................

4.4.6

Securing the lower arm ............................................................................

4.5

Frame and base ................................................................................................

4.5.1

Replacing the SMB unit ............................................................................

4.5.2

Replacing the brake release board .............................................................

4.5.3

Replacement of spherical roller bearing, balancing device ..............................

4.5.4

Replacement of balancing device ...............................................................

4.5.4.1 Replacing the balancing device ......................................................

4.5.4.2 Unloading the balancing device using hydraulic press tool ..................

4.5.4.3 Restoring the balancing device using a hydraulic press tool ................

4.6

Motors ............................................................................................................

4.6.1

Replacement of motor, axis 1 ....................................................................

4.6.2

Replacement of motor axis 2 .....................................................................

4.6.3


4.6.4


4.6.5

Replacement of motor, axis 5 ...................................................................

4.6.6


4.7

Gearboxes .......................................................................................................

4.7.1

Replacing the axis 1 gearbox .....................................................................

4.7.2

Replacement of gearbox axis 2 ..................................................................

4.7.3

Replacement of gearbox, axis 3 .................................................................

4.7.4

Replacement of gearbox, axis 6 .................................................................

343

349

356

356

368

376

383

306

313

317

320

320

325

331

338

273

283

292

296

296

299

303

306

241

246

248

254

254

258

264

5 Calibration 389

5.1

Introduction to calibration ...................................................................................

5.1.1

Introduction and calibration terminology ......................................................

5.1.2

Calibration methods .................................................................................

5.1.3

When to calibrate ...................................................................................

5.2

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 ................................................

5.3

Updating revolution counters ...............................................................................

5.4

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 ......................................

5.5

Calibrating with Calibration Pendulum method ........................................................

5.6

Verifying the calibration ......................................................................................

5.7

Checking the synchronization position ..................................................................

401

401

403

405

406

412

413

414

389

389

390

393

394

394

395

396

6 Decommissioning 417

6.1

Environmental information ..................................................................................

6.2

Scrapping of robot .............................................................................................

6.3

Decommissioning of balancing device ...................................................................

417

419

420

7 Robot description 423

7.1

Type A vs type B motors ....................................................................................

423




7


8 Spare part lists 425

8.1

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

425

9 Reference information 427

9.1

Introduction ......................................................................................................

9.2

Applicable standards .........................................................................................

9.3

Unit conversion .................................................................................................

9.4

Screw joints ....................................................................................................

9.5

Weight specifications .........................................................................................

9.6

Standard tools ..................................................................................................

9.7

Special tools ....................................................................................................

9.8

Lifting accessories and lifting instructions ..............................................................

427

428

430

431

434

435

436

440

10 Circuit diagram 441

10.1 Circuit diagrams ................................................................................................

10.2 Circuit diagram 3HAC 025744-001 ........................................................................

10.2.1 Validity of circuit diagram 3HAC025744-1 ....................................................

10.3 Circuit diagram 3HAC 13347-1 .............................................................................

10.3.1 Validity of circuit diagram 3HAC13347-1 ......................................................

441

443

443

444

444

Index 445

8




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.

The robot described in this manual has the protection type Standard and Foundry

Plus.

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 6650S. 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

Safety

Installation and commissioning

Contents

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.

Required information about lifting and installation of the robot.



Continues on next page

9



Continued

Chapter

Maintenance

Repair

Calibration

Decommissioning

Reference information

Spare part / Part list

Exploded views

Circuit diagram

Contents

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.

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

Calibration procedures and general information about calibration.

Environmental information about the robot and its components.

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

Complete spare part list and complete list of robot components, shown in the exploded views.

Detailed illustrations of the robot with reference numbers to the part list.

Reference to the circuit diagram for the robot.

References

Document name

Product specification - IRB 6650S

Product specification - IRB 6600/6650/6650S

M2000/M2000A

Product manual, spare parts - IRB 6650S

Circuit diagram

Document ID

3HAC030822-001

3HAC14064-1

3HAC049111-001

3HAC13347-1

3HAC025744-001

3HAC021313-001 Product manual - IRC5

IRC5 with main computer DSQC 639.

Product manual - IRC5

IRC5 with main computer DSQC1000.

Product manual - S4Cplus M2000

Product manual - S4Cplus M2000A

Operating manual - IRC5 with FlexPendant

User’s guide - S4Cplus (BaseWare OS 4.0)

3HAC047136-001

3HAC021333-001

3HAC022419-001

3HAC050941-001

3HAC7793-1

Operating manual - Calibration Pendulum

Operating manual - Levelmeter Calibration

Operating manual - Service Information System

Technical reference manual - Lubrication in gearboxes

Technical reference manual - System parameters

3HAC16578-1

3HAC022907-001

3HAC050944-001

3HAC042927-001

Application manual - CalibWare Field 5.0

3HAC050948-001

Application manual - Additional axes and stand alone controller

3HAC051016-001

Application manual - External axes 3HAC9299-1

3HAC030421-001

Note

M2000/M2000A

M2004

M2004

M2000/M2000A






Continued

Additional document references

Document name

CalibWare 2.0 User’s guide (M2000)

Revisions

Document ID

3HAC16090-1

E

F

G

Revision

-

A

B

C

D

H

Description

First edition.

• Model M2004 implemented.

• Product manual divided into two parts: Product manual, procedures and

Product manual, reference information .

• New foldouts: See Frame - lower arm 1 and Frame - lower arm 2 in

Product manual, spare parts - IRB 6650S .

• Updated list with special tools, section

Special tools on page 436

.

• Added spare part list, new section Spare part list in Product manual, spare parts - IRB 6650S .

Various corrections and editing made in text and figures due to technical revisions etc.

Chapter Calibration replaced with chapter Calibration information .

Section Document references is completed with article numbers for calibration manuals.

New lubricating oil in the gearboxes, axes 1, 2, 3 and 6. Changes made in:

• chapter

Maintenance on page 125

.

• This is detailed in section

Spare part lists on page 425 .

• Article number for mechanical stop set added to section

Mechanically restricting the working range of axis 2 on page 102

.

• New section added to the manual:

Installation of cooling fan for motors

(option) on page 90

.

• A complete (undivided) cabling from axis 1 to axis 6 is added to the spare parts in

Spare part lists on page 425

. New procedure

Replacing cable harness, axes 1-6 on page 219 . Also a new circuit diagram is added

to the manual, due to the new cabling.

• IRB 6650S included in section Rebuilding parts in Product manual, spare parts - IRB 6650S .

• New variant IRB 6650S - 90/3.9 is implemented throughout the manual.

Foundry Prime Option included.

Changes made in:

• Prerequisites in section Overview

• Oil change in section Maintenance

This revision includes the following additions and/or changes:

• The product name RobotStudio Online is changed to RobotStudio .

• Section " WARNING! - Mixed oils may cause severe damage to gearboxes " in chapter Safety, has been integrated in section " Type of oil in gearboxes " in the Maintenance chapter.

• The oil Shell Tivela S150 in gearboxes 1, 2, 3 and 6 has been replaced by Kyodo Yushi TMO 150 . Changes in chapters Maintenance and Spare parts .

• Modified maintenance intervals for oil change in gearboxes.

• Wrong illustration has been replaced by the correct one in " Analysis of water content in oil, gearbox axis 6 (Foundry Prime) ", section Inspection, oil level gearbox axis 6 chapter maintenance.




11



Continued

Revision

J

K

L

M

Description

• The section " Type of oil in gearboxes " in chapter Maintenance has been updated according to changes made in oil types and intervals for oil change.

• Values for tightening torque on M24 screws in chapter Reference information, added.

• Maintenance/Cleaning of robot

• Maintenance/Maintenance schedule : Interval for replacement of battery pack changed

• Maintenance/Maintenance schedule : Intervals for inspection activities and oilchanges has been revised.

• Maintenance/Maintenance schedule : Overhaul of robot is new.

• Maintenance/Maintenance schedule : The information about Service Information System (SIS) has been updated.

• Maintenance/Expected component life : The lifetime of certain parts has been revised.

• Section What is an emergency stop?

added to chapter Safety.

This revision include the following addition:

• New WARNING!

added in Safety chapter section Work inside the robot´s range .

• New WARNING!

added in Safety chapter section WARNING! - Safety risks during work with gearbox oil .

• The text in the introductions to chapters Installation , Maintenance and

Repair has been updated concerning the robot being connected to earth when power connected.

• Section Expected component life in chapter Maintenance : The lifetime of certain parts has been updated.

• Section Foundry Plus,Cable guard added to Installation chapter.

This revision includes the following additions and/or changes:

• Instruction for how to inspect oil level for wrist type 2 added, see

Inspecting the oil level in axis-6 gearbox on page 145

.

• Circuit diagrams are not included in this document but delivered as separate files. See

Circuit diagram on page 441

.

• List of standards updated, see

Applicable standards on page 428

.

• Interval changed for inspection and lubrication of balancing device

(Foundry Prime). See chapter Maintenance section

Maintenance schedule on page 127 .

The chapter Safety updated with:

• Updated safety signal graphics for the levels Danger and Warning , see

Safety signals in the manual on page 42

.

• New safety labels on the manipulators, see

Safety symbols on product labels on page 44 .

• Revised terminology: robot replaced with manipulator .

This revision includes the following updates:

• Maximum deviation changed, see

Securing the base plate on page 73 .

• New washer, see

Replacement of upper arm on page 264 .

• Corrected spare part numbers.

This revision includes following additions and/or changes:

• Removed information about lubricating attachment screws, section

Inspecting the additional mechanical stops on page 163 .

• New safety labels on the manipulators, see


• Removed incorrect article number for fork lift, see

Lifting robot with fork lift on page 61

.

• Minor adjustments made in the text concerning counters in section

Service Information System, M2000 on page 202

.






Continued

Revision

N

P

Q

Description

• Footnote about ambient temperature in maintenance schedule is deleted, see

Maintenance schedule on page 127 .

• Information about restricting and extending the working range of axis 1 is now separated, see

Mechanically restricting the working range of axis

1 on page 99

and the new section

Extended working range, axis 1 (option

561-1) on page 101 . Also added signal about option 561-1 in section

Inspecting the axis-1 mechanical stop pin on page 161 .

• Removed information about other robots than IRB 6650S from tables for oil type and amount in gearboxes, see

Type of lubrication in gearboxes on page 172

.


• A new block, about general illustrations, added in section

How to read the product manual on page 19

.

• Removed all information about Foundry Prime from the manual.

• Adjusted the forces on foundation, see

Loads on foundation, robot on page 53 .

• Added figures for installed position switches on axes 2 and 3 and attachment plate on axis 2, see

Installation of position switches (option) on page 107

.

• Made minor corrections and improvements in the complete instruction for how to replace the axis 1 gearbox, see

Replacing the axis 1 gearbox on page 356 .

• Added new mechanical structure of the lower arm attachment point for robots with protection Foundry Plus and Foundry Prime, see

Replacement of complete lower arm on page 273

and

Replacement of lower arm shaft on page 283

.

• Some general tightening torques have been changed/added, see updated values in

Screw joints on page 431 .

• Added

Safety risks during handling of batteries on page 39 .

• The maximum allowed deviation in levelity of the base plate is changed, see


• Corrected the article number for mechanical stops of axis 2, see

Mechanically restricting the working range of axis 2 on page 102

and

Inspecting the additional mechanical stops on page 163

.

• 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


• 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 172 .

• Corrected the method of inspecting oil level in the axis-6 gearbox, see

Inspecting the oil level in axis-6 gearbox on page 145 .

• Removed information about serrated lock washers from procedure

Replacement of complete arm system on page 248

.

• Corrected type of screws in Base incl frame ax 1 , see Product manual, spare parts - IRB 6650S and

Replacement of complete arm system on page 248

.


• A new SMB unit and battery is introduced, with longer battery lifetime.


• Added information about risks when scrapping a decommissioned robot, see

Scrapping of robot on page 419

.

• Spare parts and exploded views are not included in this document but delivered as a separate document. See Product manual, spare parts - IRB

6650S .




13



Continued

Revision

R

S

T

U

V

W

X

Description


• The maximum allowed deviation in levelness of the base plate and foundation is changed, see

Securing the base plate on page 73

.

• Minor corrections.


• New standard calibration method introduced (Axis Calibration). See

Calibration on page 389

.

• Tightening torque for securing screw in piston shaft front eye changed, see

Replacing the balancing device on page 306 .

• Turning disk fixture is removed from special tools for Levelmeter calibration.


• Edited information regarding deciding calibration routine in each repair section.

• Added information about inspection of calibration tool prior to usage, see

Examining the calibration tool on page 403 .

• Added a warning that calibration pin must be inserted in the calibration bushing until it snaps, see

Description of Axis Calibration on page 401 .

• Added warning regarding risk of pinching, in

Description of Axis Calibration on page 401

.

• Added information about Axis Calibration when SafeMove is installed, see

Axis Calibration with SafeMove option on page 409 .

• Added information about the calibration procedure, see

Overview of the calibration procedure on the FlexPendant on page 406

,

Restarting an interrupted calibration procedure on page 408

.

Published in release R16.2. The following updates are done in this revision:

• Drawing of base plate is not available for purchase, faulty information removed in


.

• Drawing of tool flange for LeanID added.

• Added spare part number for protection cover and plug set (Axis Calibration).

Published in release R17.1. The following updates are made in this revision:

• Removed article number for press fixture (for pressing the pinion of the axis-5 motor). The fixture is not sold by ABB.


• Caution about removing metal residues added in sections about SMB boards.

• Information about minimum resonance frequency added.

• Bending radius for static floor cables added.

• Added screw, Loctite, tightening torque and washer for wrist cover.

(Tightening torque: 14 Nm±10%, Screw 3HAB3409-25 (with Loctite),

Washer 3HAC062379-001.)

• Updated list of applicable standards.

• Added text regarding overhaul in section specification of maintenance intervals.

• Section

Start of robot in cold environments on page 124

added.

• Updated information regarding replacement of brake release board.

• Updated information regarding disconnecting and reconnecting battery cable to serial measurement board.

• Definition of reference calibration clarified.


• Information added about fatigue to Axis Calibration tool, see

Calibration tools for Axis Calibration on page 403

.






Continued

Revision

Y

Z

Description

• Updated information about locking liquid in Replacement of cable harness, axes 1-4.

• Added sections in

General procedures on page 212

.

• Safety restructured.

• Updated spare part number brake release board (was DSQC563).

• 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.

• Added Nickel in Environmental information.

• Type B motors are introduced throughout the manual.

New periodic maintenance activity regarding inspection of the type B motor oil seal.

New gasket at axis-6 motor cable inlet.

• Changed direction of installed cooling fan on axis-2 motor and removed a faulty image showing the design of the cooling fan. Also added detailed images to installation procedure for the fan.


• New dimensions added on illustration, see

Illustration, fitting of extra equipment on frame on page 84 .


• Updated references.




15

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

General

The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below:

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware will be 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 exploded views (or references to separate spare parts lists).

• Circuit diagrams (or references to circuit diagrams).

Software manuals

The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation.

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.

Each document set contains the types of information specified below:

• Installation information

• Repair information

• Maintenance information

In addition, spare part information is supplied for the entire option.

16




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.

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.





17


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.

18




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

Remove the rear attachment screws, gearbox.

Note/Illustration

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

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 21

.

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.



19


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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.





21

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.

22




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.




23

1 Safety

1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the manipulator or controller.

24




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 70 .

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.




25

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.

Spot welding cabinet

Wait for 5 minutes to let the capacitors discharge after the power has been switched off.

DANGER

Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge.

26




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.




27


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 417

for specification of allergenic materials in the product, if any.

28




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

1

2

3

Action Note

Before attempting to run the robot, make sure all emergency stop equipment is correctly installed and connected.

Emergency stop equipment such as gates, tread mats, light curtains, etc.

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.

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 .

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




29

1 Safety

1.3.3 First test run may cause injury or damage

1.3.3 First test run may cause injury or damage

Description

After installation and performing service activities, there are several safety risks to take into consideration before the first test run.

Safe handling

Use this procedure when performing the first test run after installation, maintenance, or repair.

DANGER

Running the robot without fulfilling the following aspects, may involve a risk of injury and cause severe damage to the robot.

1

2

3

4

5

6

7

Action

Remove all tools and foreign objects from the robot and its working area.

Verify that the robot is properly secured to its position by all screws, before it is powered up.

Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed.

Verify that the fixture and work piece are well secured, if applicable.

Install all safety equipment properly.

Make sure all personnel are standing at a safe distance from the robot, and is out of its reach behind safety fences, or similar.

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.

30




1 Safety

1.3.4 Work inside the working range of the robot

1.3.4 Work inside the working range of the robot

WARNING

If work must be carried out within the work area of the robot, then the following points must be observed:

• The operating mode selector on the controller must be in the manual mode position to render the three-position enabling device operational and to block operation from a computer link or remote control panel.

• The maximum speed of the robot is limited to 250 mm/s when the operating mode selector is in the position Manual mode with reduced speed . This should be the normal position when entering the working space.

The position Manual mode with full speed (100%) may only be used by trained personnel who are aware of the risks that this entails.

Manual mode with full speed (100%) is not available in USA or Canada.

• Pay attention to the rotating axes of the robot. Keep away from axes to not get entangled with hair or clothing. Also, be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell.

• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped or crushed by the robot.

• To prevent anyone else from taking control of the robot, always put a safety lock on the cell door and bring the three-position enabling device with you when entering the working space.

WARNING

NEVER , under any circumstances, stay beneath any of the robot's axes! There is always a risk that the robot will move unexpectedly when robot axes are moved using the three-position enabling device or during other work inside the working range of the robot.




31

1 Safety

1.3.5 Enabling device and hold-to-run functionality

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely.

The three-position enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, operating the robot is impossible.

Note

The three-position enabling device is a push-button located on the teach pendant which, when pressed halfway in, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state.

To ensure safe use of the teach pendant, the following must be implemented:

• The enabling device must never be rendered inoperational in any way.

• During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.

• Anyone entering the working space of the robot must always hold the teach pendant. This is to prevent anyone else from taking control of the robot without his/her knowledge.

Hold-to-run function

The hold-to-run function allows movement when a button connected to the function is actuated manually and immediately stops any movement when released. The hold-to-run function can only be used in manual mode.

How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant .

32




1 Safety

1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified electrician in accordance with electrical regulations.

Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the main switch to

OFF) when repairing faults, disconnecting electric leads, and disconnecting or connecting units.

The main supply to the robot must be connected in such a way that it can be turned off from outside the working space of the robot.

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.

The necessary protection for the electrical equipment and robot during installation, commissioning, and maintenance is guaranteed if the valid regulations are followed.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:

• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

• Units such as I/O modules, can be supplied with power from an external source.

• The main supply/main switch

• The transformers

• The power unit

• The control power supply (230 VAC)

• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)

• The drive unit (400/700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

• The power supply unit for additional tools, or special power supply units for the machining process.

• The external voltage connected to the controller remains live even when the robot is disconnected from the mains.

• Additional connections.

Voltage related risks, manipulator

A danger of low voltage is associated with the manipulator in:

• The power supply for the motors (up to 800 VDC).

• The user connections for tools or other parts of the installation (max. 230

VAC).




33


1 Safety

1.3.6 Risks associated with live electric parts

Continued

Voltage related risks, tools, material handling devices, etc.

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.

34




1 Safety

1.3.7 The unit is sensitive to ESD

1.3.7 The unit is sensitive to ESD

Description

ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics.

Safe handling

1

2

3

Action Note

Use a wrist strap. The wrist strap button is located inside the controller.

Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

• Product manual - IRC5

• Product manual - IRC5 Panel Mounted

Controller

Use an ESD protective floor mat.

Use a dissipative table mat.

The mat must be grounded through a current-limiting resistor.

The mat should provide a controlled discharge of static voltages and must be grounded.




35

1 Safety

1.3.8 Hot parts may cause burns

1.3.8 Hot parts may cause burns

Description

During normal operation, many parts become hot. Touching these may cause burns.

There is also a risk of fire if flammable materials are put on hot surfaces.

Safe handling

Always use your hand, at some distance, to feel if heat is radiating from the potentially hot component before actually touching it.

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.

36




1 Safety

1.3.9 Safety risks related to pneumatic/hydraulic systems

1.3.9 Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from the power supply must be provided with clearly visible drain facilities and a warning sign that indicates the need for pressure relief before adjustments or performing any maintenance on the robot system.

Residual energy

Residual energy can be present in these systems. After shutdown, particular care must be taken.

The pressure must be released in the complete pneumatic or hydraulic systems before starting to repair them.

Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics.

All pipes, hoses, and connections have to be inspected regularly for leaks and damage. Damage must be repaired immediately.

Splashed oil may cause injury or fire.

Safe design

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.




37

1 Safety

1.3.10 Brake testing

1.3.10 Brake testing

When to test

During operation, the holding brake of each axis normally wears down. A test can be performed to determine whether the brake can still perform its function.

How to test

The function of the holding brake of each axis motor may be verified as described below:

1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized (maximum static load).

2 Switch the motor to the MOTORS OFF.

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.

38




1 Safety

1.3.11 Safety risks during handling of batteries

1.3.11 Safety risks during handling of batteries

Description

Under normal conditions of use, the electrode materials and liquid electrolyte in the batteries are not exposed to the outside, provided the battery integrity is maintained and seals remain intact.

There is a risk of exposure only in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery container. Electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Safe handling

Use safety glasses when handling the batteries.

In the event of leakage, wear rubber gloves and chemical apron.

In the event of fire, use self-contained breathing apparatus.

Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge or expose to temperatures above the declared operating temperature range of the product. Risk of fire or explosion.

Operating temperatures are listed in

Pre-installation procedure on page 52

.




39

1 Safety

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

Description

When handling gearbox lubricants, there is a risk of both personal injury and product damage occurring. The following safety information must be regarded before performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety information of the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must be provided. Gloves and goggles are recommended.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Safe handling

Warning Description Elimination/Action

Changing and draining gearbox oil or grease may require handling hot lubricant heated up to

90 °C.

Make sure that protective gear like goggles and gloves are always worn during this activity.

Hot oil or grease

When working with gearbox lubricant there is a risk of an allergic reaction.

Make sure that protective gear like goggles and gloves are always worn.

Allergic reaction

Possible pressure build-up in gearbox

When opening the oil or grease plug, there may be pressure present in the gearbox, causing lubricant to spray from the opening.

Open the plug carefully and keep away from the opening. Do not overfill the gearbox when filling.


40




1 Safety

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

Continued

Warning

Do not overfill

Description Elimination/Action

Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may:

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the robot from moving freely.

Make sure not to overfill the gearbox when filling it with oil or grease.

After filling, verify that the level is correct.

Do not mix types of oil

Mixing types of oil may cause severe damage to the gearbox.

When filling gearbox oil, do not mix different types of oil unless specified in the instructions. Always use the type of oil specified by the manufacturer.

Warm oil drains quicker than cold oil.

When changing gearbox oil, first run the robot for a time to heat up the oil.

Heat up the oil

Specified amount depends on drained volume

The specified amount of oil or grease is based on the total volume of the gearbox. When changing the lubricant, the amount refilled may differ from the specified amount, depending on how much has previously been drained from the gearbox.

After filling, verify that the level is correct.

Contaminated oil in gear boxes

When draining the oil make sure that as much oil as possible is drained from the gearbox. The reason for this is to drain as much oil sludge and metal chips as possible from the gearbox.

The magnetic oil plugs will take care of any remaining metal chips.




41

1 Safety

1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal consists of:

• A caption specifying the danger level (DANGER, WARNING, or CAUTION) and the type of danger.

• A brief description of what will happen if the the danger is not eliminated.

• Instruction about how to eliminate danger to simplify doing the work.

Danger levels

The table below defines the captions specifying the danger levels used throughout this manual.

Symbol Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Significance

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, and so on.

Warns that an accident may occur if the instructions are not followed that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, etc.

Warns for electrical hazards which could result in severe personal injury or death.

CAUTION Warns that an accident may occur if the instructions are not followed that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment where there is a risk of damaging the product or causing a breakdown.

ELECTROSTATIC

DISCHARGE (ESD)

Warns for electrostatic hazards which could result in severe damage to the product.


42




Symbol Designation

NOTE

1 Safety

1.4.1 Safety signals in the manual

Continued

Significance

Describes important facts and conditions.

TIP Describes where to find additional information or how to do an operation in an easier way.




43

1 Safety

1.4.2 Safety symbols on product labels

1.4.2 Safety symbols on product labels

Introduction to labels

This section describes safety symbols used on labels (stickers) on the product.

Symbols are used in combinations on the labels, describing each specific warning.

The descriptions in this section are generic, the labels can contain additional information such as values.

Note

The safety and health symbols on the labels on the product must be observed.

Additional safety information given by the system builder or integrator must also be observed.

Types of labels

Both the manipulator and the controller are marked with several safety and information labels, containing important information about the product. The information is useful for all personnel handling the robot, for example during installation, service, or operation.

The safety labels are language independent, they only use graphics. See

Symbols on safety labels on page 44

.

The information labels can contain information in text (English, German, and

French).

Symbols on safety labels

Symbol xx0900000812 xx0900000811

Description

Warning!

Warns that an accident may occur if the instructions are not followed that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, etc.

Caution!

Warns that an accident may occur if the instructions are not followed that can result in injury and/or damage to the product.

It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment where there is a risk of damaging the product or causing a breakdown.

Prohibition

Used in combinations with other symbols.

xx0900000839





Symbol xx0900000813

1 Safety


Continued

Description

See user documentation

Read user documentation for details.

Which manual to read is defined by the symbol:

• No text: Product manual .

• EPS: Application manual - Electronic Position Switches .

Before disassemble, see product manual xx0900000816

Do not disassemble

Disassembling this part can cause injury.

xx0900000815

Extended rotation

This axis has extended rotation (working area) compared to standard.

xx0900000814 xx0900000808

Brake release

Pressing this button will release the brakes. This means that the robot arm can fall down.





45

1 Safety


Continued

Symbol Description

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


46




Symbol

1 Safety


Continued

Description

Heat

Risk of heat that can cause burns. (Both signs are used) xx0900000818

!

xx1300001087

1 xx0900000819

3

4

5

2

6

Moving robot

The robot can move unexpectedly.

xx1000001141

2

4

3

1 xx1500002616





47

1 Safety


Continued

Symbol Description

Brake release buttons xx0900000820 xx1000001140 xx0900000821

Lifting bolt

Chain sling with shortener xx1000001242

Lifting of robot xx0900000822

Oil

Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Mechanical stop xx0900000824


48




1 Safety


Continued

Description

No mechanical stop

Symbol xx1000001144 xx0900000825

Stored energy

Warns that this part contains stored energy.

Used in combination with Do not disassemble symbol.

Pressure

Warns that this part is pressurized. Usually contains additional text with the pressure level.

xx0900000826

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




49


2 Installation and commissioning

2.1 Introduction


2.1 Introduction

General

This chapter contains assembly instructions and information for installing the IRB

6650S at the working site.

More detailed technical data can be found in the Product specification for the IRB

6650S, such as:

• Load diagram

• Permitted extra loads (equipment), if any

• Location of extra loads (equipment), if any.


Before any installation work is commenced, it is extremely important that all safety information is observed.

There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing the procedures. Read the chapter

Safety on page 21

before performing any installation work.

Note

If the IRB 6650S is connected to power, always make sure that the robot is connected to protective earth before starting any installation work.

For more information see:





51


2.2.1 Pre-installation procedure

2.2 Unpacking

2.2.1 Pre-installation procedure

Introduction

This section is intended for use when unpacking and installing the robot for the first time. 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.

Checking the pre-requisites for installation

1

2

3

Action

Make a visual inspection of the packaging and make sure that nothing is damaged.

Remove the packaging.

Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damages are found.

4

5

6

7

8

9

10

11

Clean the unit with a lint-free cloth, if necessary.

Make sure that the lifting accessory used (if required) is suitable to handle the weight of the robot as specified in:

Weight, robot on page 53

If the robot is not installed directly, it must be stored as described in:

Storage conditions, robot on page 55

Make sure that the expected operating environment of the robot conforms to the specifications as described in:

Operating conditions, robot on page 55

Before taking the robot to its installation site, make sure that the site conforms to:

•

Loads on foundation, robot on page 53

•

Protection classes, robot on page 55

•

Requirements, foundation on page 54

Before moving the robot, please observe the stability of the robot:

Risk of tipping/stability on page 60

When these prerequisites are met, the robot can be taken to its installation site as described in section:

On-site installation on page 61

Install required equipment, if any.

•

Signal lamp (option) on page 87


52






Continued

Weight, robot

The table shows the weight of the robot.

The weight does not include the weight of the DressPack.

Robot model

IRB 6650S

Weight

2275 kg

Note

The weight does not include tools and other equipment fitted on the robot.

The weight does not include the weight of the DressPack.

Loads on foundation, robot

The illustration shows the directions of the robots stress forces.

The directions are valid for all floor mounted, suspended and inverted robots.

T xy

F z

F xy

T z xx1100000521

F xy

F z

T xy

T z

Force in any direction in the XY plane

Force in the Z plane

Bending torque in any direction in the XY plane

Bending torque in the Z plane

The table shows the various forces and torques working on the robot during different kinds of operation.

Note

These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time!




53




Continued

WARNING

The robot installation is restricted to the mounting options given in following load table(s).

Floor mounted

Force

Force xy

Force z

Torque xy

Torque z

Endurance load (in operation)

± 10.6 kN

28.2 ± 7.7 kN

± 28.2 kNm

± 31 kNm*

± 7.9 kNm

Max. load (emergency stop)

± 20.9 kN

28.2 ± 16.4 kN

± 50.5 kNm

± 55.6 kNm*

± 13.6 kNm

Requirements, foundation

The table shows the requirements for the foundation where the weight of the installed robot is included:

Requirement

Flatness of foundation surface

Maximum tilt

Minimum resonance frequency

Value

0.3 mm

Note

Flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from ABB.

The value for levelness aims at the circumstance of the anchoring points in the robot base.

In order to compensate for an uneven surface, the robot can be recalibrated during installation.

If resolver/encoder calibration is changed this will influence the absolute accuracy.

5°

22 Hz

Note

It may affect the manipulator lifetime to have a lower resonance frequency than recommended.

The value is recommended for optimal performance.

Due to foundation stiffness, consider robot mass including equipment.

i

For information about compensating for foundation flexibility, see Application manual - Controller software IRC5 , section Motion Process Mode .

i

The minimum resonance frequency given should be interpreted as the frequency of the robot mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e., the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent mass of the floor is very high, it will not affect robot movement, even if the frequency is well below the stated 25 Hz. The robot should be mounted as rigid as possibly to the floor.

Disturbances from other machinery will affect the robot and the tool accuracy. The robot has resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified, although somewhat damped by the servo control. This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment.


54






Continued

Storage conditions, robot

The table shows the allowed storage conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient temperature (less than 24 hrs)

Maximum ambient humidity

Value

-25° C

+55° C

+70° C

95% at constant temperature

(gaseous only)

Operating conditions, robot

The table shows the allowed operating conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient humidity

Value

+5°

+50°

Max. 95% at constant temperature.

Protection classes, robot

The table shows the available protection types of the robot, with the corresponding protection class.

Protection type

Manipulator, protection type Standard

Manipulator, protection type Foundry Plus

Protection class

IP 67

IP 67




55


2.2.2 Working range and type of motion

2.2.2 Working range and type of motion

Working range

The following figures show the working ranges of the robot variants. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm).

IRB 6650S - 200/3.0

The illustration below shows the unrestricted working range of IRB 6650S - 200/3.0: xx0300000562


56






Continued

IRB 6650S - 125/3.5






57



Continued

IRB 6650S - 90/3.9


A Marked area: max. payload 50 kg


58






Continued

Turning radius

The turning radius, shown as A in the figure below, is specified for the different robot variants below the figure.

Type of motion xx0600002740

IRB 6650S - 200/3.0

IRB 6650S - 125/3.5

IRB 6650S - 90/3.9

3039 mm

3485 mm

3932 mm

5

6

3

4

Axis

1

2

Type of motion

Rotation motion

Arm motion

Arm motion

Wrist motion

Bend motion

Turn motion

Range of movement

+180° to -180°

+160º to -40º

+70º to -180º

+300° to -300°

+120° to -120°

+300° to -300°

Note

+220º to -220º (option 561-1)




59


2.2.3 Risk of tipping/stability

2.2.3 Risk of tipping/stability

Risk of tipping

If the robot is not fastened to the foundation while moving the arm, the robot is not stable in the whole working area. Moving the arm will displace the center of gravity, which may cause the robot to tip over.

The shipping position is the most stable position.

Do not change the robot position before securing it to the foundation!

Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.

xx0300000632

WARNING

The robot is likely to be mechanically unstable if not secured to the foundation.

60





2.3.1 Lifting robot with fork lift

2.3 On-site installation

2.3.1 Lifting robot with fork lift

General

The robot may be moved using a fork lift, provided that available special aids are used.

This section describes how to attach the fork lift equipment to the robot.

Attachment points on robot

The attachment points for the fork lift equipment are shown in this figure.

Notice the length of the IRB 6650S balancing device when planning to lift with a fork lift, shown in the figure below.

xx0300000463

A

B

C



Attachment points, spacer and horizontal attachment screws

Attachment points, horizontal attachment screws

Attachment points, vertical attachment screws


61




Continued

D Attachment points, horizontal attachment screws

Required equipment

Equipment, etc.

Standard toolkit

Art. no.

Fork lift accessory, incl. all required hardware

3HAC0604-2

-

Note

Content is defined in section

Standard tools on page 435

.

Fork lift accessory, 3HAC0604-2

The Fork lift accessory, 3HAC0604-2, is fitted to the robot as shown in the figure below.

xx0200000379

A

B

C

D

Fork lift pocket (2 pcs, 3HAC15766-1 , 3HAC11264-1)

Spacer (2 pcs)

Horizontal attachment screws (4 pcs/ fork lift pocket)

Vertical attachment screws (2 pcs)


62






Continued

Lifting robot with fork lift

This section details how to secure the fork lift set to the robot in order to lift and move the robot using the fork lift ONLY!

1

2

Action

If a cooling fan for the axis 1 motor is used, it must be removed in order to use the fork lift device!

Note

Position the robot as shown in the figure to the right!

Release the brakes if required as detailed in section

Manually releasing the brakes on page 70

.

xx0300000632

3 Fit the two spacers to the robot and secure.

Attachment points are shown in figure

Attachment points on robot on page 61 .

4

CAUTION

The fork lift pocket weighs 60 kg!

5 Secure the longer fork lift pocket to the spacers with four of the horizontal attachment screws and washers.

Note

The screws, which are attached horizontally and vertically, are identical. However, they are tightened with different torque!

Always use original screws (or replacements of equivalent quality: M16, quality 12.9)!

Attachment points on the robot are shown in figure


xx0400001068

A Horizontal attachment screws, 4 pcs, M16 x 60. Tightening torque:

60 Nm.

B Spacers, 2 pcs.





63



Continued

6

Action

Make sure the securing screw is fitted to the longer fork lift pocket.

It prevents the fork of the fork lift to be inserted too far into the pocket and thereby damaging the motor of axis 2.

Note

7 Secure fork lift pocket to robot with two vertical attachment screws and washers.

Note

Vertically and the horizontally attached screws are identical, but tightened with different torques!

xx0400000977

A Securing screw xx0300000464

A Vertical attachment screws, 2 pcs, M16x60. Tightening torque:

270 Nm.


Attachment points on robot are shown in figure


8

CAUTION

The fork lift pocket weighs 22 kg!

9 Secure the shorter fork lift pocket on the other side of the robot with the four remaining horizontal attachment screws .

4 pcs, M16x60.

Tightening torque: 60 Nm.


Attachment points on robot are shown in figure



64






Continued

Action

10 Double-check that pockets are properly secured to the robot! Insert fork lift forks into the pockets.

Note

11

CAUTION

The IRB 6650S robot weighs 2275 kg.

All lifting accessories used must be sized accordingly!

xx0200000380

Reposition harness, if any, before using a fork lift!

12 Carefully lift the robot and move it to its installation site.

13

WARNING

Personnel must not, under any circumstances, be present under the suspended load!

14 Refit the cooling fan to the motor, if any.




65


2.3.2 Lifting robot with roundslings

2.3.2 Lifting robot with roundslings

General

The robot can be lifted with roundslings according to this section.

Sling specification

Sling type

Chain sling with shortener

Qty

4 pcs

Lifting capacity

4 000 kg

Length / Note

0.43 m

0.605 m

0.75 m

0.785 m

2 m Roundsling, robot 4 pcs 2 000 kg

Lifting with roundslings

1

2

Action

Position robot in a secure transport position.

Note

Attach roundslings to robot according to figure

Attachment points on page 67 .

3

CAUTION



4

WARNING



66





2.3.2 Lifting robot with roundslings

Continued

Attachment points

This figure shows how to attach the roundslings to the robot.

The illustration is similar with the label attached to the robot’s lower arm.

xx0400000679

A

B

C

Chain sling with shortener

Roundsling, robot

Roundsling, used to secure against rotation




67


2.3.3 Lifting robot with lifting slings

2.3.3 Lifting robot with lifting slings

General

This section contains a general overview of how to lift the complete robot using special lifting equipment. More detailed instructions are included with the equipment.

Note

Move the robot to the recommended position shown in the figure and in the instruction!

Attempting to lift a robot in any other position may result in the robot tipping over, causing severe damage or injury!

Illustration, lifting slings

The figure below shows how to lift the complete robot with lifting slings.

xx0400000722


Equipment

Lifting accessory, robot

Article number

3HAC15607-1

Note

Includes user instructions 3HAC15971-2


68





2.3.3 Lifting robot with lifting slings

Continued

Slings attached directly onto robot

This section details how to lift and move the robot using lifting slings when these are attached directly onto the robot frame.

1

2

3

Action

Run the overhead crane to a position above the robot.

Note

Position the robot as detailed in enclosed instruction!

Article number is specified in

Required equipment on page 68 .

Release the brakes, if required, as detailed in section


Fit the lifting accessory to the robot as described in the enclosed instruction!



4

CAUTION



5

WARNING


6 Raise overhead crane to lift the robot.

Make sure all hooks and attachments maintain their correct positions while lifting the robot!

Always move the robot at very low speeds, making sure it does not tip.




69


2.3.4 Manually releasing the brakes

2.3.4 Manually releasing the brakes

Introduction to manually releasing the brakes

This section describes how to release the holding brakes for the motors of each axis.

Location of brake release unit

The internal brake release unit is located as shown in the figure.

xx0300000564

Releasing the brakes

This procedure details how to release the holding brakes when the robot is equipped with an internal brake release unit.

1

Action Note

The internal brake release unit is equipped with buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.

If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to the section

Supplying power to connector R1.MP

on page 71

.

Buttons are shown in figure

Location of brake release unit on page 70 .

2

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.

3 Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release unit.

The brake will function again as soon as the button is released.


70





2.3.4 Manually releasing the brakes

Continued

Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector

R1.MP on the robot, in order to enable the brake release buttons.

Action Note

1

DANGER

Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously!

2 Supply 0V on pin 12 and 24V on pin 11.

xx0600002937




71


2.3.5 Lifting the base plate

2.3.5 Lifting the base plate


Equipment

Lifting eye, M16

Lifting slings

Hole configuration

Article number

3HAC14457-4

Note

3 pcs

Length: approx. 2 m xx0200000096

A Attachment holes for lifting eyes (x3)

Lifting, base plate

Action Note

1

2

3

CAUTION

The base plate weighs 353 kg. All lifting accessories used must be sized accordingly.

Fit lifting eyes in specified holes.

Fit lifting slings to the eyes and to the lifting accessory.

Shown in figure

Hole configuration on page 72

.

CAUTION

Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage.

72





2.3.6 Securing the base plate

2.3.6 Securing the base plate

Base plate, dimensions

D G

F

B

B

H

2x R525

598,31

560,85

487,01

(Ø 80

0)

12x M24

Ø1 A

455

243,5

A

A

E

0

73,84

111,30

C C

2x 50x45º

4x4

8

0.3

Common Zone

E, F, G, H

A

A-A

Ø 45P7

Ø1.5

3x4

5º

857,3

1020

13

(2

)

(4

8)

B-B

(4x)

6,3

(2

)

1,6

3x4

5º

(2

)

13

3x R1

45

K

7 c

47

0

+0

,5

5

2

,5º

0,25 c

(2

)

(2x R22,5)

3x4

3x 90º

C-C D

1,6 xx1000001053

E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other)





73



Continued xx0400000715

A Four holes for alternative clamping, 4x Ø18


74






Continued

Base plate, orienting grooves and leveling bolts

The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate.

B A

B

A

B

B

A xx1500000312

A

B

Orienting grooves (3 pcs)

Levelling bolts, attachment holes (4 pcs)





75



Continued

Base plate, guide sleeve holes

The illustration below shows the orienting grooves and guide sleeve holes in the base plate.

A xx0300000045

A Guide sleeve holes (2 pcs)


Equipment

Base plate

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

-

Article number Note

3HAC12937-8 Includes

• guide sleeves, 3HAC12937-3

• levelling screws, 9ADA120-79

• attachment screws and washers for securing the robot to the base plate.


Standard tools on page 435 .

These procedures include references to the tools required.

Base plate

This section details how to secure the base plate to the foundation.

1

Action

Make sure the foundation is levelled.

Note







Continued

Action Note

2

CAUTION

The base plate weighs 353 kg! All lifting equipment used must be sized accordingly!

3

4

5

6

7

8

9

Position base plate in relation to the robot work location using the grooves in the base plate.

Lift the base plate to its mounting position.

Shown in figure

Base plate, orienting grooves and leveling bolts on page 75 .

Detailed in section

Lifting the base plate on page 72 .

Use the base plate as a template and drill attachment holes as required by the selected bolt dimension.

Attachment holes: 16 pcs.

Fit the base plate and use the levelling bolts to level the base plate.

Shown in figure

Base plate, orienting grooves and leveling bolts on page 75 .

If required, fit strips of sheet metal underneath the base plate to fill any gaps.

Secure the base plate to the foundation with screws and sleeves.

Recheck the four contact surfaces on the base plate to make sure the base plate is levelled and flat.

If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position.

Maximum allowed deviation all over the base plate, from one contact surface to the other: 0.3 mm.




77


2.3.7 Orienting and securing the robot

2.3.7 Orienting and securing the robot

General

This section details how to orient and secure the robot to the base plate in order to run the robot safely.

Illustration, robot fitted to base plate

This illustration shows the robot base fitted to the base plate.

xx0100000107

A

B

C

D

Robot attachment bolts and washers, 12 pcs (M24 x 140)

Orienting grooves in the robot base and in the base plate

Levelling screws

Base plate attachment screws

Attachment screws

The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate/foundation.

Suitable screws, lightly lubricated:

Quality:

Suitable washer:

Tightening torque:

M24 x 140

Quality 8.8

Thickness: 4 mm

Outer diameter: 44 mm

Inner diameter: 25 mm

725 Nm


78






Continued

Securing the robot

Use this procedure to secure robot to base plate after fitting plate to the foundation.

1

2

3

Action

Lift the robot.

Note

See section

Lifting robot with lifting slings on page 68 .

See section

Lifting robot with roundslings on page 66 .

Move robot to the vicinity of its installation location.

Fit two guide sleeves to the guide sleeve holes in the base plate.

Shown in figure

Base plate, guide sleeve holes on page 76 .

Note

One of the guide sleeve holes is elongated!

4

5

Guide the robot gently using two M24 screws while lowering it into its mounting position.

Fit the bolts and washers in the base attachment holes.

Make sure the robot base is correctly fitted onto the guide sleeves!

Specified in

Attachment screws on page 78 .

Shown in figure

Illustration, robot fitted to base plate on page 78 .

Note

Lightly lubricate screws before assembly!

6 Tighten bolts in a criss-cross pattern to ensure that the base is not distorted.





79



Continued

Hole configuration, base

This illustration shows the hole configuration used when securing the robot.

xx0300000046

Cross section, guide sleeve hole

This illustration shows the cross section of the guide sleeve holes.

80 xx0600002629





2.3.8 Fitting equipment on robot

2.3.8 Fitting equipment on robot

General

The robot features mounting holes for additional equipment.

Access to any of the following mounting holes may be obstructed by any additional cabling, equipment, etc., fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell.

Note

All equipment and cables used on the robot, must be designed and fitted not to damage the robot and/or its parts.

Note

The robot IRB 6600ID, IRB 6650ID and IRB 6650ID is delivered with DressPack and there may not be any additional equipment fitted to the robot, except at the turning disc and the frame.

Illustration, fitting of extra equipment on lower arm

The illustration below shows the mounting holes available for fitting extra equipment on the lower arm.

Make sure not to damage the robot cabling on the inside of the lower arm when fitting extra equipment. Always use appropriate attachment screws!

xx0300000568





81



Continued xx0300000569 xx0300000570


82






Continued

Illustration, fitting of extra equipment on upper arm

The illustration below shows the mounting holes available for fitting extra equipment on the upper arm.

xx0300000574 xx0200000196

Only valid for IRB 6600 and IRB 6650





83



Continued

Illustration, fitting of extra equipment on frame

The mounting holes available for fitting extra equipment on the frame are shown below.

480 240

6x M16 xx0300000575

800

1180


84






Continued

Tool flange, standard

The illustration below shows the mounting holes available for fitting equipment on the turning disc.

xx0200000197





85



Continued

Tool flange, LeanID

The illustration below shows the tool flange for option 780-4 LeanID.

B

1,6

+1

15 0

0,02 A

100 H7

99

M12 (9x)

0,3 A B

0,5 x45

J R 2

R0,8

R 1 30°

B-B

C

R 80

I

J

B B

60°

H xx1600000979

172 ±0,2

C-C

C

60°

C

Fastener quality

When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9.

Standard screws with quality 8.8 may be used when fitting other equipment to the mounting holes.

86





2.3.9 Signal lamp (option)

2.3.9 Signal lamp (option)

Description

A signal lamp with a yellow fixed light can be mounted on the robot, as a safety device.

Installation

See the assembly instruction delivered with the signal lamp.

Function

The lamp is active in MOTORS ON mode.

Further information

Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller.




87


2.3.10 Installation of base spacers (option)

2.3.10 Installation of base spacers (option)

Illustration, installation of base spacers xx0500001570

A

B

C

Base spacer (4 pcs)

Guide sleeve (4 pcs)

Attachment screws and washers (8 pcs)


Equipment

Base spacers

Art. no.

3HAC021899-002

Base plate

Standard toolkit


88

-

3HAC12937-8


Note

Includes mounting set with attachment screws and mounting instruction.






2.3.10 Installation of base spacers (option)

Continued

Equipment

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

Art. no.

Note


Installation, base spacers

The procedure below details how to fit the base spacers between the robot and the base plate.

Action Note

1

DANGER

Turn off all:

• electric power supply to the robot

• hydraulic pressure supply to the robot

• air pressure supply to the robot

Before entering the robot working area.

2

3

4

5

6

7

Unfasten the robot from the foundation, if fastened, and lift it away with lifting slings.

Make sure the robot is positioned in the most stable position; the transport position!

Install the base plate to the foundation, if not used previously.

Fit the four base spacers and guiding sleeves to the base plate.

Detailed in section

Lifting robot with lifting slings on page 68 .

Detailed in section


.

Shown in the figure

Illustration, installation of base spacers on page 88

.

Lift the robot with lifting slings and move it to the prepared base plate.

Guide the robot with the guiding sleeves as lowering it towards the base plate and spacers.

Fasten the robot base to the spacers with enclosed attachment screws and washers.

M24 x 240, tightening torque: 775 Nm.

8

DANGER

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 30 .




89


2.3.11 Installation of cooling fan for motors (option)

2.3.11 Installation of cooling fan for motors (option)

General

A cooling fan can be installed on the motors of axes 1, 2 and 3.

Cooling fans for axes 1 and 2 can not be combined!

The cabling for the fans is available in different designs:

• complete cabling, including connections for both cooling fans and position switches, at axes 1, 2 and 3. Installation of this complete cabling is detailed in section

Installation of cable harness for position switches and fans on page 115 .

• separate cabling for axis 1 or 2, including only connections for the cooling fans on axes 1 or 2. Installation of this cabling is detailed in section

Installation, separate fan cabling axis 1 or 2 on page 94 .

Location of cooling fans

The fans are installed on the motors, axes 1 or 2, as shown in the figure below.

xx1800000169

A

B

Cooling fan, axis 1

Cooling fan, axis 2 xx1800000170


90




Cooling fan



Continued

The details of the cooling fan are shown in the figure below.

xx0500002158

A

B

C

D

Fanbox

Attachment screws, fanbox plates (9 pcs)

Groove in the connector

Tightening screws, fanbox (3 pcs)


Equipment

Cooling fan

Cabling cooling fan, axes 1 or 2.

Plate for customer connections

Article number

3HAC15374-1

3HAC023599-001

3HAC025778-001

Note

Choose this cabling if equipping the robot with cooling fans on axis 1 or 2.

An additional connection plate must be fitted to the robot base, if not already installed. The plate is shown in the figure

Plate for customer connections, at base on page 92

.

Additional cabling to and inside the controller

-

Material set fan axes 1 and

2

3HAC023999-001 The set includes:

• fan axes 1 & 2 cable harness

• plate, customer

• attachment screws and nuts.

Cable harness inside controller

3HAC025488-001




91




Continued

Equipment

Locking liquid

Standard toolkit

Circuit diagram


-

Plate for customer connections, at base

-

-


Loctite 243. Used for the three tightening screws.



.

See chapter

Circuit diagram on page 441 .


xx0500002301

A

B


Attachment screws, 3 pcs, M6x16 quality 8.8-A2F


92






Continued

Installation, fan

The procedure below details how to install the cooling fan on any of the motors, axes 1-3 .

Action Note

1

DANGER

Turn off all:





2 Prepare the fanbox for installation:

• disassemble the two parts of the box by removing the nine attachment screws

• loosen the three tightening screws , to avoid damaging the surfaces of the motor when fitting the fanbox

• turn the connector to the correct position; axis 1: groove pointing inwards, as shown in the figure

Cooling fan on page 91

. Positions for axis 2 and 3 are shown in the figure

Location of cooling fans on page 90 .

Shown in the figure

Cooling fan on page 91

.

3 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox.

4

5

Fit the parts of the fanbox to the motor and reassemble with the nine attachment screws .

Lift the box (axis 1) so that it does not rest directly on the robot and secure the box with the three tightening screws, using locking liquid. Tighten them properly so that the box is firmly attached to the motor.

6 Install the cabling and make adjustments in RobotWare, as described in the following procedures.

Separate cabling for axis 1 or 2

The figure below shows the cabling used only for the fan on axis 1 or 2.

xx0500002173





93



Continued

A

B

C

Cable bracket

Connector R1.SW2/3, connected to the robot base

Connector R3.FAN2, connected to the fan of axis 1 or 2

Installation, separate fan cabling axis 1 or 2

The procedure below details how to install the separate cabling for the cooling fan of axis 1 or 2.

1

Action

Move the robot to its calibration position.

Note

This is detailed in section

Synchronization marks and synchronization position for axes on page 394

.

2

DANGER

3

Turn off all:





Remove the rear cover plate from the robot base.

4

5 xx1800000161

Remove the cable bracket (A) Shown in the figure

Separate cabling for axis 1 or 2 on page 93

Fit the plate for customer connections , if not already fitted, to the connection plate of the robot base.

Art. no. is specified in

Required equipment on page 91

.

6 Run the cabling up through the base and frame, beneath the balancing device.

xx1800000162


94






Continued

7

Action

Secure the cable bracket to the bracket of the robot cabling inside the frame.

Run the cable underneath the robot cabling and out through the side of the frame, at motor, axis

1 . The correct cable run is shown in the figure to the right!

Note

Note

There is a risk of the balancing device damaging the cable if it is not protected by the robot cabling!

8

9

10

11 xx0500002174

A Cable bracket. Also shown in the figure

Separate cabling for axis 1 or 2 on page 93

.

Connect the connector R3.FAN2 to the fan of axis

1 or 2.

Note

Fans on both axis 1 and 2 can not be used at the same time!

Connect the connector R1.SW2/3 to the base of the robot. Make sure that the cabling, run through the frame and base, is not twisted and runs freely from the robot cabling.

Refit the rear cover plate to the robot base.

Install additional cabling to and inside the controller.

Also make adjustments in RobotWare, as described in the following procedure.

Adjustments in RobotWare

1

Action

Modify the settings in RobotWare to include the cooling fans.

Note

RobotWare 4.0: modify the settings in RobInstall. RobotWare 4.063 and older must be updated with a newer release.

RobotWare 5.0: change the settings in the

Modifying options dialogue, by using the

Modify Controller System Wizard in the System Builder of RobotStudio. Read more about modifying the system in Operating manual -

RobotStudio .



95



2.3.12 Installation of Foundry Plus Cable guard (option no. 908-1)

2.3.12 Installation of Foundry Plus Cable guard (option no. 908-1)

Introduction

How to install the Foundry Plus Cable guard is described in the instruction delivered with the cable guard.

Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found for registered users on myABB Business Portal (www.myportal.abb.com) and delivered with the Cable guard, article number 3HAC035933-001.

96





2.3.13 Loads fitted to the robot, stopping time and braking distances

2.3.13 Loads fitted to the robot, stopping time and braking distances

General

Any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and mass moments of inertia) in order to avoid jolting movements and overloading motors, gears and structure.

CAUTION

Incorrectly defined loads may result in operational stops or major damage to the robot.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the product specification. The loads must be defined in the software.

• User’s guide - S4Cplus (BaseWare OS 4.0)

• Operating manual - IRC5 with FlexPendant

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.




97


2.4.1 Axes with restricted working range

2.4 Restricting the working range

2.4.1 Axes with restricted working range

General

When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited.

The working range of the following axes may be restricted:

• Axis 1, hardware (mechanical stop) and software (signal from adjustable position switch)



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.

98





2.4.2 Mechanically restricting the working range of axis 1

2.4.2 Mechanically restricting the working range of axis 1

General

The working range of axis 1 is limited by fixed mechanical stops and adjustment of the system parameter configuration. The working range can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5° and 135° in both directions.

Mechanical stops, axis 1

The illustration shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1.

xx0300000049

A

B

Additional mechanical stop

Stop pin


Equipment, etc.

Mechanical stop for axis 1, 7.5°

Mechanical stop for axis 1, 15°

Standard toolkit -

Article number

3HAC11076-1

3HAC11076-2

Note

Includes attachment screws and an assembly drawing.

Includes attachment screws and an assembly drawing.







Continued

Equipment, etc.

User’s guide - S4Cplus (BaseWare OS

4.0) (BaseWare 4.0)


-


Article number is specified in section

References on page 10 .

Installation, mechanical stops axis 1

Use this procedure to fit the additional mechanical stops to axis 1 of the robot. An assembly drawing is also enclosed with the product.

Action Note

1

DANGER

Turn off all:





2

3

Fit the additional mechanical stop to the frame according to the figure

Mechanical stops, axis 1 on page 99 .


Adjust the software working range limitations

(system parameter configuration) to correspond to the mechanical limitations.

How to define the range of movement in

RobotWare 4.0 is detailed in User’s guide - S4Cplus (BaseWare OS 4.0), chapter System Parameters - topic Manipulator .

The system parameters that must be changed ( Upper joint bound and Lower joint bound ) are described in Technical reference manual - System parameters .

4

WARNING

If the mechanical stop pin is deformed after a hard collision, it must be replaced!

Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision.

100





2.4.3 Extended working range, axis 1 (option 561-1)

2.4.3 Extended working range, axis 1 (option 561-1)

Overview

The working range of axis 1 can be increased from standard range to extended ±

220º.

Extending the working range

1

Action

Remove the mechanical stop pin from axis

1 (A).

Note/Illustration xx0400001034

2

3

4

Option 561-1 requires installation of option

810-1 Electronic Position Switch es.

Configure Electronic Position Switches.

See Application manual - Electronic Position Switches

Option 561-1 requires installation of option

25-3 Position switches axis 1 .

Install position switches at axis 1.

See

Installation of position switches (option) on page 107 .

Redefine the software working range limitations in the system parameters, topic

Motion . The Arm parameters Upper Joint

Bound and Lower Joint Bound must be changed to 3.84 respectively -3.84. The values are in radians, that is 3.84 radians

= 220 degrees.







101




General

The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.


The illustration shows the mounting position of the mechanical stops on axis 2.

xx0300000047

A

B

Additional mechanical stops

Fixed mechanical stop


Equipment, etc.

Art. no.

Mechanical stop set, axis 2 3HAC13787-1

Standard toolkit -

User’s guide - S4Cplus

(BaseWare OS 4.0) (Robot-

Ware 4.0)


-


102


Note

Includes six stops, attachment screws, washers and assembly drawings.



.

Art. no. is specified in section






Continued


Use the procedure to fit the mechanical stops for axis 2 to the robot. An assembly drawing is also enclosed with the product.

Action Note

1

DANGER

Turn off all:





2

3

Fit and tighten the additional stops in a row, starting from the fixed stop.


Shown in the figure

Mechanical stops, axis 2 on page 102

.

The software working range limitations must be redefined to correspond to the changes in the mechanical limitations of the working range.




4

WARNING






103




General

The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.


The illustration shows the mounting position of the mechanical stops on axis 3.

The figure shows IRB 7600 but the principle is the same.

xx0300000048

A

B

C

Additional mechanical stops

Fixed mechanical stop

Attachment screw M16x60 quality 12.9


104







A

B

Mechanical stop pin, axis 3

Attachment screw and washer


Equipment, etc.

Mechanical stop set, axis 3

Art. no.

3HAC13128-1

Standard toolkit

User’s guide - S4Cplus (Base-

Ware OS 4.0) (RobotWare 4.0)


-

-

Note

Includes:

• six stops, one with 80° restriction, 3HAC12708-3 (use when limitation angle >=80), and five with 20°, 3HAC12708-1.

• attachment screws.



.







105



Continued


Use the procedure to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product.

Action Note

1

DANGER

Turn off all:





2

3

Fit and tighten the additional stops in a row, starting from the fixed stop.


Shown in the figure

Mechanical stops, axis 3 on page 104

Note

The software working range limitations

(system parameters) must be redefined to correspond to the changes in the mechanical limitations of the working range.




4

WARNING



106





2.4.6 Installation of position switches (option)

2.4.6 Installation of position switches (option)

General

Position switches can be installed on axes 1-3. The position switches include cams as shown in the figures below. The system parameter configuration must also be updated.

The position switch kits may be delivered in one of two ways:

• Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.

• As kits to be completely fitted to the robot and adjusted by the user.


Description

Position switch, axis 1



Cabling, position switches and cooling fans, axes 1, 2 and 3

Attachment plate for axis-2 switch

3HAC021884-001

3HAC16417-2

3HAC16659-1

3HAC020113-001

Plate for customer connections 3HAC025778-001

Additional cabling to and inside the controller

Connector kit R1.SW1

Connector kit R1.SW2/3

-

Art. no.

3HAC15715-1

3HAC17252-1

3HAC17253-1

Note

Includes position swtich and plate for customer connections.

Includes only the position switch.

Includes only the position switch.

Cabling to be installed on the robot.

See

Illustration, attachment plate for axis-2 switch on page 113

.

An additional connection plate must be fitted to the robot base, if not already installed. The plate is shown in the figure

Plate for customer connections, at base on page 114 .

Specified in section

Robot cabling and connection points on page 119 .





107



Continued

Axis 1

The illustration below shows the position switch for axis 1. There is no extra cabling installed on the robot, as for axes 2 and 3. Instead the switch is connected directly to the connector in the base, R1.SW1.

xx0100000158

A

B

C

D

E

F


Cam

Set screw, cam (cam stop)

Protection sheet

Rail

Rail attachment


108




Axis 2



Continued

The illustration below shows the position switch for axis 2. In addition to the shown components, cabling must also be installed from the switch to the robot base.

xx0400001038

C

D

A

B


Cam

Rail

Rail attachment





109



Continued

Axis 3

The illustration below shows the position switch for axis 3. In addition to the shown components, cabling must also be installed from the switch to the robot base.

Specifications xx0100000160

A

B

C

E

F


Cam

Set screw, cam (cam stop)

Rail

Rail attachment

Maximum voltage/current for the position switches:

Parameter

Voltage

Current

Value

Max. 50 VDC

Max. 1 A


110






Continued

Connections

The position switches are connected to different points on the robot system:

• XT8, screw terminal in the controller cabinet when position switch cables are used.

• R1.SW1 at the robot base. Customer connection kit is recommended, art.

no. is specified in

Required equipment on page 107 !

• R1.SW2/3 at the robot base. Customer connection kit is recommended, art.

no. is specified in


Further information about the cables and connection points, see section

Robot cabling and connection points on page 119

.

Installation of position switch, axis 2

3

4

5

1

2

Action

Remove the cable protection from the lower arm.

Fit the rail by pushing it against the support surface on the lower arm and tightening the two screws.

Fit the cam and the position switch unit.

Refit the cable protection to the lower arm with two screws.

Adjust the software working range limitations (system parameter configuration) to correspond to the mechanical limitations.


Fitting and adjusting cams and stops

The instruction below details how to fit and adjust the parts of the position switches:

1

2

3

4

5

6

Action

Cut the cam to a suitable length.

Cut the edge of the cam edge to max 30°!

Note

Use a sharp knife and rubber hammer or similar.

Shown in

Illustration, cutting the cam on page 112 .

If the angle is larger, this may damage the position switch!

Cut the part of the cam running in the profile to 90°!

Also see

Illustration, cutting the cam on page 112

below!

Make sure the ends of the profile are chamfered to enable the cam to run through the profile.

Fit the cam with the M5 screw and nut. Tighten the M5 screw to secure the cam.

Shown in

Illustration, adjust and secure cams on page 112 .

Install the cabling for axes 2 and/or 3.

Detailed in section

Installation of cable harness for position switches and fans on page 115 .





111



Continued

Illustration, adjust and secure cams

The illustration below show how to adjust and secure the position switch cams and profiles.

xx0100000113

A

B

C

Cam stop, M5 nut and M5 x 6 set screw

Adjustable cam

Profile

Illustration, cutting the cam

The illustration below show how to cut the position switch cam.

xx0100000114

A Remove the gray section


112




Illustration, attachment plate for axis-2 switch

A








113



Continued

Plate for customer connections, at base xx0500002301

A

B


Attachment screws, 3 pcs, M6x16


114




Cable harness for position switches and fans, axes 1-3




A

B

C

Cable bracket, frame

Cable bracket, lower arm

Cable bracket, upper arm

R1.SW2/3 Connected to the robot base

R3.FAN2

Connected to the fan of axis 1 or 2

R3.FAN3

Connected to the fan of axis 3

R2.SW2

R2.SW3

Connected to the position switch of axis 2

Connected to the position switch of axis 3

Installation of cable harness for position switches and fans

The procedure below details how to fit the complete cable harness for position switches and cooling fans to the robot.

1

2

Action


Note

DANGER

Turn off all:









115



Continued

3

Action

Remove the rear cover (A) from the robot base and replace the protection (B) with a plate for customer connections (if not already mounted).

Note

4

5

Run the cabling through the base and frame of the robot, up beneath the balancing device.

Run and secure the cabling inside the frame as detailed below and as shown in the figure to the right:

• Secure the cable bracket (A) to the bracket of the robot cabling.

• Run the cable for the fan of axis 1 or

2 under the robot cabling and through the side of the frame at motor axis 1.

• Secure the cabling going up to the axis 3 fan and position switch with existing velcro strap (B), attached around the robot cabling.

• Connect the connector R2.SW2 to the position switch of axis 2.

Note

There is a risk of the balancing device damaging the fan cable if it is not protected by correct routing underneath the robot cabling!

xx0500002306

Art. no. for the plate is specified in


xx0500002309

A Cable bracket, frame. Also shown in the figure

Cable harness for position switches and fans, axes 1-3 on page 115

.

B Velcro strap

C Connector R2.SW2


116






Continued

6

Action

Connect the connector R3.FAN2 to the fan of either axis 1 or axis 2.

If no fan is used, strap the cabling together with the motor cabling so that the connector stays close to the frame, as shown in the figure to the right.

Note

7 Run the remaining cable harness up through the lower arm and:

• secure with the bracket, lower arm , as shown in the figure to the right.

• connect the connector R2.SW3 to the position switch of axis 3.

• secure the cable going to the fan of axis 3, together with the robot cabling with a velcro strap.

xx0500002312

8 xx0500002313

A Bracket, lower arm. Also shown in the figure

Cable harness for position switches and fans, axes 1-3 on page 115 .

B Bracket for robot cabling

C Connector R2.SW3

D Velcro strap

Secure the axis 3 fan cable with the bracket, upper arm .

Shown in the figure

Cable harness for position switches and fans, axes 1-3 on page 115

.




117




Continued

9

Action

Connect the connector R3.FAN3 to the fan of axis 3. If no fan is used, strap the cable together with the robot cabling.

Note xx0500002314

10

11

12

Connect the connector R1.SW2/3 to the base of the robot. Make sure that the cabling, run through the base, frame and lower arm, is not twisted and is running free from the robot cabling.

Refit the rear cover to the robot base.

Install additional cabling to and inside the control cabinet.

Cabling is specified in section:

•

Position switch cables, robot base to controller (option) on page 121

118





2.5.1 Robot cabling and connection points

2.5 Electrical connections

2.5.1 Robot cabling and connection points

Introduction

Connect the robot and controller to each other after securing them to the foundation.

The lists below specify which cables to use for each respective application.

Main cable categories

All cables between the robot and controller are divided into the following categories:

Cable category

Robot cables

Description

Handles power supply to and control of the robot's motors as well as feedback from the serial measurement board.

Specified in the table

Robot cables on page 119 .

Position switch cables (option)

Also includes fan cables.

Handles supply to and feedback from any position switch on the robot.

Also handles supply to and feedback from cooling fans.


Position switch cables, robot base to controller (option) on page 121

.

Fan cables (option)

Customer cables (option)

Handles supply to and feedback from any cooling fan on the robot.


Fan cables (option) on page 122 .

Handles communication with equipment fitted on the robot by the customer, low voltage signals and high voltage power supply + protective ground.

The customer cables also handle databus communication.

See the product manual for the controller, see document number in


External axes cables (option) Handles power supply to and control of the external axes' motors as well as feedback from the servo system.

See the Application manual - Additional axes and stand alone controller (M2004) or Application manual - External axes (M2000) , see document number in

References on page 10

.

Robot cables

These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.

Cable sub-category

Robot cable, power

Robot cable, signals

Description

Transfers resolver data from and power supply to the serial measurement board.

Connection point, cabinet

Transfers drive power from the drive units in the control cabinet to the robot motors.

XS1

XS2

Connection point, robot

R1.MP

R1.SMB





119



Continued

Robot cable, power

Cable

Robot cable, power: 7 m




Art. no.

3HAC026787-001

3HAC026787-002

3HAC026787-003

3HAC026787-004

Robot cable, signals

Cable

Robot cable signal, shielded: 7 m




Art. no.

3HAC7998-1

3HAC7998-2

3HAC7998-3

3HAC7998-4

Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.

A

B xx1600002016

A

B

Diameter

Diameter x10


120






Continued

Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices.

xx1500001599

Position switch cables, robot base to controller (option)

These cables are not included in the standard delivery, but are included in the delivery if the position switch option is ordered. The position switches can also be ordered without cables. The cables are completely pre-manufactured and ready to plug in.

Cabling to be installed on the robot is specified in sections and


.

Cabling between robot base and controller

In a M2000 and M2000A robot system, the cables specified below are used for both position switches and cooling fans.

In a M2004 robot system, however, the cables below are only used for position switches. Cabling for the cooling fans is specified in the table

Fan cables (option) on page 122 .

Cable Art. no.

Position switch cable, axis 1, 7 m




3HAC13175-1

3HAC13175-2

3HAC13175-3

3HAC13175-4

Position switch cable, axes 2 and 3, 7 m 3HAC13176-1




R1.SW

R1.SW

R1.SW

R1.SW

R1.SW2/3

R1.SW2/3

R1.SW2/3


XS8

XS8

XS8

XS8

XS58

XS58

XS58




121




Continued

Cable Art. no.



R1.SW2/3


XS58

Cabling inside control cabinet

Additional cabling must be connected inside the control cabinet when installing position switches.

Additional cabling must also be connected inside the control cabinet when installing fans for robot systems M2000 and M2000A (fan cabling for M2004 runs all the way from the robot base to the inside of the cabinet and the additional cabling specified below is therefor not needed).

Cable Art. no.

Bracket in the cabinet wall (M2000 and M2000A)

3HAB7286-5

Bracket in the cabinet wall (M2004) 3HAC020813-082

Harness position switch (M2000) 3HAC15899-1

Harness position switch axis 1

(M2004)

Harness position switch axes 2 and

3 (M2004)

3HAC021117-001

3HAC021116-001

Cable harness fans (M2000)

3HAC15666-1

-

Connection point 1 inside cabinet

-

XS58

XS8

XS58

XS57

-

Connection point 2 inside cabinet

-

XP57

XT8.1 and XT8.2

XT58.1 and

XT58.2

XT31

Fan cables (option)

These cables are not included in the standard delivery, but are included in the delivery if the fan option is ordered. The cables are completely pre-manufactured and ready to plug in.

Cabling to be installed on the robot is specified in section

Installation of cooling fan for motors (option) on page 90

.

Cabling between robot base and control cabinet, cooling fans, M2004

The cables specified below are specific for the IRC5 controller and used when the robot is equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot base to the inside of the cabinet. Fans can also be ordered without cables.

If equipping the robot with cooling fans, use the cabling specified below. The cables for cooling fans listed below are used together with a distributing cable, also specified below.

Cable

Harness - cooling, 7 m

Art. no.

3HAC022723-001

Harness - cooling, 15 m 3HAC022723-004

Harness - cooling, 22 m 3HAC022723-005

Connection point

Distributing cable: R1.FAN.SW2/3

Inside cabinet: A43.X10 and A43.X11











Continued

Cable

Harness - cooling, 30 m

Art. no.

3HAC022723-006

Connection point






123


2.6 Start of robot in cold environments

2.6 Start of robot in cold environments

Introduction

This section describes how to start the robot in a cold environment if it is not starting the normal way.

Problems with starting the robot

Event message from Motion Supervision

Use this procedure if an event message indicates a problem with Motion supervision at start-up. More information about Motion Supervision is found in Technical reference manual - System parameters .

1

2

3

Action

Turn off Motion Supervision.

Start the robot.

When the robot has reached normal working temperature, the Motion Supervision can be turned on again.

Note

Robot stopping with other event message

Use this procedure if the robot is not starting.

1

Action

Start the robot with its normal program but with reduced speed.

Note

The speed can be regulated with the

RAPID instruction VelSet .

Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the speed might need to be ramped up until reached maximum. The table shows examples of how to adjust the speed:

Work cycles

3 Work cycles

5 Work cycles

5 Work cycles

5 Work cycles

More than 5 Work cycles

AccSet

20, 20

40, 40

60, 60

100, 100

100, 100

Speed/velocity v100 (100 mm/s) v400 (400 mm/s) v600 (600 mm/s) v1000 (1000 mm/s)

Max.

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.

124




3 Maintenance

3.1 Introduction

3 Maintenance


Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB

6650S.

It is based on the maintenance schedule found at the beginning of the chapter.

The schedule contains information about required maintenance activities including intervals, and refers to procedures for the activities.

Each procedure contains all the information required to perform the activity, including required tools and materials.

The procedures are gathered in different sections and divided according to the maintenance activity.


Observe all safety information before conducting any service work.

There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing the procedures. Read the chapter

Safety on page 21

before performing any service work.

Note

If the IRB 6650S is connected to power, always make sure that the IRB 6650S is connected to protective earth before starting any maintenance work.






125

3 Maintenance

3.2.1 Specification of maintenance intervals

3.2 Maintenance schedule and expected component life

3.2.1 Specification of maintenance intervals

Introduction

The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 6650S:

• Calendar time: specified in months regardless of whether the system is running or not.

• Operating time: specified in operating hours. More frequent running means more frequent maintenance activities.

• SIS: specified by the robot's SIS (Service Information System). A typical value is given for a typical work cycle, but the value will differ depending on how hard each part is run. The SIS used in M2000 and M2000A is further described in the section


.

The SIS used in M2004 is further described in the Operating manual - Service

Information System .

Overhaul

Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours.

ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working.

Contact your local ABB Customer Service to get more information.

126




3 Maintenance

3.2.2 Maintenance schedule

3.2.2 Maintenance schedule

General

The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the following table.

Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately!

The inspection intervals do not specify the life of each component. Values for these are specified in the section

Expected component life on page 131

Instructions for how to perform the different maintenance activities are found in sections:

•

Inspection activities on page 132

•

Replacement/changing activities on page 172

•

Cleaning activities on page 199

Activities and intervals, standard equipment

The following table specifies the required maintenance activities and intervals.

Interval Detailed in section Maintenance activity

Equipment

Cleaning Robot -

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Motor seal i

Oil level in axis-1 gearbox






Balancing device

Every:

• 12 months

Every:

12 months

Every:

12 months

Every:

12 months

Every:

12 months

Every:

12 months

Every:

12 months

Every:

• 6 months

Robot harness

Information labels

Every:

12 months ii

Every:

• 12 months

Dampers Every:

• 12 months

•

Cleaning the IRB

6650S on page 199

Inspecting the motor seal on page 132







•

Inspecting the balancing device on page 150

•

Inspecting the cable harness on page 155

•

Inspecting the information labels on page 159

Inspecting the damper on axes 2-5 on page 166




127


3 Maintenance


Continued

Maintenance activity

Equipment

Inspection

Changing

Changing

Changing

Changing

Changing

Changing

Changing

Changing

Changing

Mechanical stops

Interval

Every:

• 12 months

Detailed in section

•

Inspecting the axis-

1 mechanical stop pin on page 161

•


Oil in axis-1 gearbox:


Kyodo Yushi TMO

150

Every:

• 12,000 hours

First change when DTC iii reads:

6,000 hours

Second change when DTC

iii

reads:

24,000 hours

Following changes:

Every 24,000 hours


Optigear Synthetic

RO

Every:

• 12,000 hours


Kyodo Yushi TMO

150

First change when DTC reads:

iii

6,000 hours


iii

reads:

24,000 hours

Following changes:

Every 24,000 hours

Changing oil, axis-1 gearbox on page 174

Do not mix with other oils!

•

Changing oil, axis-1

•

gearbox on page 174



•


•



Optigear Synthetic

RO

Every:

• 12,000 hours


Kyodo Yushi TMO

150


iii

6,000 hours


iii

reads:

24,000 hours

Following changes:

Every 24,000 hours

Oil in axis-4 gearbox


Every:

24,000 hours

Every:

24,000 hours


•

•

•





Every:

• 12,000 hours

•



128




3 Maintenance


Continued


Equipment Interval Detailed in section

Changing

Overhaul


Kyodo Yushi TMO

150

Robot


iii

6,000 hours


iii

reads:

24,000 hours

Following changes:

Every 24,000 hours

Every:

40,000 hours


•

•


Expected component life on page 131

Replacement Battery pack, measurement system of type

RMU101 or

RMU102 (3-pole battery contact)

36 months or battery low alert iv

Replacement Battery pack, measurement system with 2-pole battery contact, e.g.

DSQC633A

Battery low alert v

•

•

Replacing the SMB battery on page 192

Replacing the SMB battery on page 192

Lubrication Balancing device bearings

Every:

12,000 hours vi i

Only valid for robots that are equipped with Type B motors.

Type B motors include evacuation on the motor flange to indicate failure of primary sealing between the gearbox and the motor. Robots with protection type Foundry Plus have a sight glass installed in the evacuation holes.

See

Type A vs type B motors on page 423

.

ii

Replace when damage or cracks is detected or life limit is approaching that specified in section

Expected component life on page 131 .

iii

DTC = Duty Time Counter. Shows the operational time of the robot.

iv The battery low alert (38213

Battery charge low ) is displayed when the battery needs to be replaced.

The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

See the replacement instruction for more details.

v

The battery low alert (38213 Battery charge low ) is displayed when remaining backup capacity

(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the robot is powered off 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.

vi Always lubricate the front eye bearing after refitting the shaft of the balancing device.

Activities and intervals, optional equipment

The following table specifies the required maintenance activities and intervals for common optional equipment. The maintenance of other external equipment for the robot is detailed in separate documents.

Equipment Interval Note Detailed in section Maintenance activity

Inspection

Inspection

Signal lamp Every:

12 months

Mechanical stop axes 1-2-3

Every:

12 months

Inspecting, signal lamp on page 170





129


3 Maintenance


Continued


Inspection

Equipment Interval

Position switches, axes 1-

2-3

Every:

12 months

Note Detailed in section

Inspection, position switch axes 1, 2 and

3 on page 168

130




3 Maintenance

3.2.3 Expected component life

3.2.3 Expected component life

General

The expected life of a specific component of the robot can vary greatly depending on how hard it is run.

Expected component life - protection type Standard

Component

Cable harness

Normal usage i

Expected life

40,000 hours ii

Note

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Cable harness

Extreme usage iii

20,000 hours

ii

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Balancing device

Gearboxes v

40,000 hours

40,000 hours iv i

Examples of "normal usage" in regard to movement: most material handling applications and limited use of bending backwards mode of axis 3.

ii

Severe chemical or thermal environments, or similar environments, can result in shortened life expectancy.

iii iv The given life for the balancing device is based on a test cycle of 4,000,000 cycles that starts from the initial position and goes to maximum extension, and back. Deviations from this cycle will result in differences in expected life!

v

Examples of "extreme usage" in regard to movement: press tending, very severe palletizing applications, major use of axis 1 movement and major use of bending backwards of axis 3.

Depending on application, the lifetime can vary. The Service Information System (SIS) that is integrated in the robot software can be used as guidance when planning gearbox service for the individual robot. This applies to gearboxes on axes 1, 2, 3 and 6. The lifetime of gearbox axes 4 and 5 is not calculated by SIS (See the Operating manual - Service Information System ). In some applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB

Robotics Service team for more information.

The SIS for an IRC5 system is described in the Operating manual - Service Information System .

For an M2000 system, the SIS is described in section


.




131

3 Maintenance

3.3.1 Inspecting the motor seal

3.3 Inspection activities

3.3.1 Inspecting the motor seal

Purpose of evacuation holes

This section is only valid for robots that are equipped with Type B motors.

The motors include evacuation on the motor flange to indicate failure of primary sealing between the gearbox and the motor.

More information is found in

Type A vs type B motors on page 423 .

Location of evacuation hole on motor

The evacuation hole is located on each motor flange. The figure shows axis-1 motor as an example.

xx1500001057

Plug in the evacuation hole

Robots with protection type Standard have a protection filter installed in the evacuation hole.

Robots with protection type Foundry Plus have a transparent plug/sight glass installed in the evacuation holes.

xx1800000101

Protection filter (Standard).


132 xx1800000102

Transparent plug (Foundry Plus).




3 Maintenance

3.3.1 Inspecting the motor seal

Continued

Inspecting the evacuation hole

Action

1

DANGER

Turn off all:

• electric power supply

• hydraulic pressure supply

• air pressure supply to the robot, before entering the robot working area.

2

WARNING

Handling gearbox oil involves several safety risks.

Before proceeding, please read the safety information in the section

Safety risks during work with gearbox lubricants (oil or grease) on page 40 .

Note

3 Do a leakage check of the sight glass/evacuation hole of each motor.

If any oil is available on the sight glass or if any oil has been spilled out from the evacuation hole, replacement of the motor is recommended.

xx1500001057

Replacing of motors is described in the repair chapter

Motors on page 320 .




133

3 Maintenance

3.3.2 Inspecting the oil level in axis-1 gearbox

3.3.2 Inspecting the oil level in axis-1 gearbox

Location of gearbox

The axis-1 gearbox is located between the frame and base. See oil plugs in the following figure.

xx0300000583

A

B

Oil plug, inspection

Oil plug, filling


Equipment

Lubricating oil

Standard toolkit


-

Art. no.

See


Note

Note









3 Maintenance


Continued

Inspecting the oil level in axis-1 gearbox

Use this procedure to inspect the oil level in the axis-1 gearbox.

Action Note

1

WARNING



Safety risks during work with gearbox lubricants (oil or grease) on page 40

.

2

3

4

5

DANGER

Turn off all:




Make sure that the oil temperature is +25°C ±10°C.

This is a precaution to reduce the temperature dependency of the measurement.

Open the oil plug, inspection .

Measure the oil level.

Required oil level: max. 10 mm below the oil plug hole.

Shown in figure

Location of gearbox on page 134 .

A

6 Adjust the oil level, if required.

7

8

Refit the oil plug.

WARNING

Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes .

B

C xx1400002785

A Oil plug hole

B Required oil level

C Gearbox oil

Where to find type of oil and total amount is detailed in

Type of lubrication in gearboxes on page 172 .

Further information about how to fill with oil is found in section

Changing oil, axis-1 gearbox on page 174 .

Tightening torque:24 Nm



135


3 Maintenance




The axis-2 gearbox is located in the lower arm rotational center, underneath the motor attachment.

xx0300000631

A

B

C

Oil plug, filling and inspection

Oil plug, draining

Vent hole, gearbox axis 2


Equipment, etc.,

Lubricating oil

Standard toolkit


-

Art. no.

Note

See

Type and amount of oil in gearboxes on page 172

.

Note!






136




3 Maintenance


Continued



Action Note

1

WARNING

Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section


2

3

4

5

DANGER

Turn off all:





Make sure that the oil temperature is +25°C

±10°C.


Open the oil plug, filling and inspection .


Required oil level: max. 5 mm below the inspection oil plug hole.

Shown in the figure


A


7

8

Refit the oil plug.

WARNING


B

C xx1400002785

A Oil plug hole


C Gearbox oil



Filling of oil is detailed further in the section

Filling, oil on page 178

.




137


3 Maintenance




The axis 3 gearbox is located in the upper arm rotational center as shown in the figure.

xx0200000230

A

B

C

Gearbox axis 3


Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit -

Art. no.

Note

See


Note!








3 Maintenance


Continued

Equipment, etc.


Art. no.

Note




Action Note

1

WARNING



2 Move the robot to a position according to the illustration in


Detailed in the section

Synchronization marks and synchronization position for axes on page 394 .

3

DANGER

Turn off all:





4

5

6


±10°C.



Required oil level: max. 5 mm below the filling oil plug hole.


Shown in the figure


A

B

C xx1400002785

A Oil plug hole


C Gearbox oil





139

3 Maintenance


Continued

7

Action

Adjust the oil level, if required.

8

9

Refit the oil plug.

WARNING


Note



Further information about how to fill the oil may be found in the section

Filling, oil on page 182 .


140




3 Maintenance




The axis-4 gearbox is located in the rear part of the upper arm as shown in the figure.

xx0200000231

A

B


Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit


-

Art. no.

See


Note



.




Action Note

1

WARNING






141


3 Maintenance


Continued

2

Action

Move the robot to the calibration position.

Note



.

3

4

5

6

DANGER

Turn off all:






±10°C.



Shown in the figure

Location of gearbox on page 141

.

A Measure the oil level.

Required oil level: 0-10 mm


8

9

Refit the oil plug.

WARNING


B

C xx1400002785

A Oil plug hole


C Gearbox oil




Filling, oil on page 184

.


142




3 Maintenance




The axis-5 gearbox is located in the wrist unit as shown in the figure.

xx0200000232

-

A

B

The figure above shows the wrist unit of IRB 6600 and IRB 6650


Oil plug, draining


Equipment etc.

Lubricating oil

-

Art. no.

See


.

Note

Standard toolkit







Action Note

1

WARNING







143


3 Maintenance


Continued

2

3

Action

Move the robot upper arm to a horizontal position.

Turn the wrist unit in a way that both oil plugs are facing upwards.

Note

4

DANGER

Turn off all:





5 Make sure that the oil temperature is +25°C

±10°C.

6 Open the oil plug, filling and inspection .


Shown in the figure


7 Measure the oil level.

Required oil level to the upper edge of the filling and inspection oil plug hole (a): 30 mm xx0500002222


9

10

Refit the oil plug.

WARNING





Filling, oil, axis 5 on page 187 .


144




3 Maintenance




The axis-6 gearbox is located in the wrist unit as shown in this figure.

A

B

C xx0600002964

Type 1

Axis-6 gearbox


Oil plug, draining xx0400001092

A

B

C

Type 2

Axis-6 gearbox


Oil plug, draining

Inspection depending on type of wrist

To inspect oil level for wrist type 1, see

Inspecting the oil level in axis-6 gearbox, wrist type 1 on page 146

.

To inspect oil level for wrist type 2, see

Inspecting the oil level in axis-6 gearbox, wrist type 2 on page 148

.




145


3 Maintenance


Continued


Equipment

Lubricating oil

-

Art. no.

See


Note

Standard toolkit





Inspecting the oil level in axis-6 gearbox, wrist type 1

Use this procedure to inspect the oil level in the axis-6 gearbox, for wrist type 1.

Action Note

1

WARNING




2 Move axes 3 and 5 to a horizontal position, and make sure that the oil plug, filling and inspection is facing upwards.

3

DANGER

Turn off all:





4

5

Make sure that the oil temperature is +25°C ±10°C.



A xx1300000244


146




3 Maintenance


Continued

6

7

Action

Turn axis 6 so that the oil plug, draining faces upwards.

Open the oil plug, draining .

Note

This is a precaution to avoid vacuum effects by allowing air to enter at the top of the gearbox.

Note

If equipment that covers the oil plug, draining is fitted on the robot so that the oil plug cannot be opened, then this step can be skipped.

8

9

Slowly turn axis 4, while adjusting axis 6 so that the oil plug, draining always faces upwards. Turn axis

4 until the axis-4 angle reads -45° to -55°.

Inspect the oil level in the hole for the oil plug, filling and inspection .

The oil should reach all the way up to the external edge of the thread for the oil plug, filling and inspection .

C

A

B

Note

If the oil plug, draining is not opened, then use a clean, narrow object, for example an oil stick or a cable tie, to gently poke the oil surface. This will avoid surface tension from stopping air to enter into the gearbox.

xx1400002786

A Oil plug hole


C Gearbox oil




.


Filling, oil, axis 6 on page 190

.


11

12

Refit the oil plugs.

WARNING






147

3 Maintenance


Continued

Inspecting the oil level in axis-6 gearbox, wrist type 2

Use this procedure to inspect the oil level in the axis-6 gearbox, for wrist type 2.

Action Note

1

WARNING



2 Move axes 3 and 5 to a horizontal position, and make sure that the oil plug, filling and inspection is facing upwards.

3

DANGER

Turn off all:





4 Make sure that the oil temperature is +25°C

±10°C.


5 Remove the oil plug, filling and inspection .

xx1300002447

6

7

Slowly turn axis 4 until the axis-4 angle reads

+72.5° to +77.5°.

Inspect the oil level in the hole for the oil plug, filling and inspection .

The oil should reach all the way up to the external edge of the thread for the oil plug, filling and inspection .

C

A

B

Note

If needed, use a clean, narrow object, for example an oil stick or a cable tie, to gently poke the oil surface. This will avoid surface tension from stopping air to enter into the gearbox.

xx1400002786

A Oil plug hole


C Gearbox oil





3 Maintenance


Continued

8

Action

Adjust the oil level, if required.

9

10

Refit the oil plug.

WARNING


Note



.


Filling, oil, axis 6 on page 190 .





149

3 Maintenance

3.3.8 Inspecting the balancing device

3.3.8 Inspecting the balancing device

General

Several points are to be checked on the balancing device during the inspection.

This section describes how to perform the inspection regarding:

• dissonance

• damage

• leakage

• contamination / lack of free space.

Inspection points, balancing device

The balancing device is located at the top rear of the frame as shown in the figure.

The figure also shows the inspection points, further described in the instructions.

xx0400001025

E

F

G

A

B

C

D

Balancing device

Piston rod (inside)

Shaft, including securing screw

Ear, bearing and o-rings

Label with article number

Inspect the surroundings

Bearing, balancing device attachments


150




3 Maintenance


Continued


Equipment, etc.

Maintenance kit, complete

-

Spare part no.

Maintenance kit, bearings and seals

-

Securing screw

Toolkit for maintenance

Puller for separator

Separator

Standard toolkit

Art. no.

4552-2 (Bahco)

4551-C (Bahco)

3HAC15571-1

Note

Includes:

• complete kit including the kit with bearings and seals

• instructions for maintenance.

Includes:

• kit with bearings, orings and seals only

• instructions for maintenance.

Securing screw in the shaft.

M16 x 180

Locking liquid must be used when fitting the screw (Loctite

243)!

See chapter Reference information .

Used for removing the spherical roller bearings.

Used for removing the spherical roller bearings.



.



Check for dissonance

The check points are shown in the figure

Inspection points, balancing device on page 150

.

1

2

Check for dissonance from...

If dissonance is detected...

• bearing at the link ear

• bearings at the balancing devices attachments.

... perform maintenance according to given instructions in Maintenance kit, bearings and seals. The replacement of the bearing at the ear is also detailed in section

Replacement of spherical roller bearing, balancing device on page 303 .

Art. no. for the kit and the documentation are specified in section


• balancing device (a tapping sound, caused by the springs inside the cylinder).

...replace the balancing device or consult ABB Robotics.

How to replace the device is detailed in section

Replacing the balancing device on page 306 . This section also

specifies the spare part number!




151


3 Maintenance


Continued

3

Check for dissonance from...

If dissonance is detected...

• piston rod (squeaking may indicate worn plain bearings, internal contamination or insufficient lubrication).

... perform maintenance according to given instructions in Maintenance kit, complete.



Check for damage

Check for damages, such as scratches, general wear, uneven surfaces or incorrect positions.

The check points are shown in the figure


.

1

2

Check for damage on...

If damage is detected...

• the piston rod (part of the piston rod that is visible at the front of the balancing device).

... perform maintenance according to given instructions in Maintenance kit, complete.



• the securing screw in the front ear shaft.

Also check the tightening torque (50 Nm).

...replace.

Dimension is specified in section


.

Check for leakage

The front ear of the balancing device is lubricated with grease. After filling, excessive grease may normally be forced out between the shaft and the sealing ring in the sealing spacer. This is normal behaviour and must not be confused with incorrect leaks from the ear.

Leaks at the o-rings and/or sealings, are not acceptable and must be attended to immediately in order to avoid any damage to the bearing!


152




3 Maintenance


Continued

Check the o-rings in the front ear of the balancing device for leaks, as shown and detailed below.

xx0400001026

C

D

A

B

E

F

Shaft

O-ring

Sealing spacer

Sealing ring in sealing spacer

Correct way out for excessive grease from inside the front ear

Incorrect leakage from the front ear

1

2

Action

Clean the area at the front ear from old grease.

Note

Run the robot for some minutes, in order to move the balancing device piston.





153

3 Maintenance


Continued

3

Action Note

Check the o-rings at the front ear for leakage.

Replace the o-rings, if any leaks are detected.

Excessive grease from between the shaft and the sealing ring is normal and is not considered as a leak!

The o-rings are included in the Maintenance kit, bearings and seals , already assembled with sealing spacers and sealing rings.

Art. no. for the kit is specified in


.

The replacement of the complete bearing is also detailed in section

Replacement of spherical roller bearing, balancing device on page 303 .

Incorrect leakage is shown in the previous figure.

Check for contamination / lack of free space

Action

1

DANGER

Turn off all:





2 Check that there are no obstacles inside the frame, that could prevent the balancing device from moving freely. See the figure


.

Keep the areas around the balancing device clean and free from objects, such as service tools.

154




3 Maintenance

3.3.9 Inspecting the cable harness

3.3.9 Inspecting the cable harness

Location of cable harness, axes 1-4

The robot cable harness, axes 1-4, is located as shown in the figure below.

Note!

The cable harness is also available without the division point R2.M5/6. Except for the connectors at the division point, the rest of the inspection points are the same for the harness that runs undivided from axis 1 to axis 6.

xx0200000097

A

B

C

D

Lower arm

Cables attached with velcro straps and mounting plate

Connectors at cable harness division point, R2.M5/6

Connectors at base


Equipment, etc.

Standard toolkit -

Art. no.

Note



.





155

3 Maintenance


Continued

Equipment, etc.


Circuit diagram

Art. no.

Note


See chapter


.

Inspection, cable harness 1-4

The procedure below details how to inspect the cable harness of axes 1-4.

Action Note

1

DANGER

2

3

4

5

Turn off all:





Make an overall visual inspection of the cable harness, in order to detect wear and damage.

Check the connectors at the division point and at the base.

Shown in the figure

Location of cable harness, axes 1-4 on page 155

.

Check that velcro straps and the mounting plate are properly attached to the frame. Also check the cabling, leading into the lower arm.

Make sure it is attached by the straps and not damaged.

Location is shown in the figure

Location of cable harness, axes 1-4 on page 155 .

A certain wear of the hose at the entrance to the lower arm is natural.

Replace the cable harness if wear, cracks or damage is detected.

Described in section

Replacing cable harness, axes 1-6 on page 219 .


156




3 Maintenance


Continued

Location of cabling axes 5-6

The robot cable harness, axes 5-6, is located as shown in the figure below.

Note!

The cable harness is also available without the division point R2.M5/6. Except for the connectors at the division point, the rest of the inspection points are the same for the harness that runs undivided from axis 1 to axis 6.

xx0200000234

A

B

C

Connectors at cable harness division point, R2.M5/6

Cable attachment, rear of upper arm

Cable attachment, upper arm tube

Inspection, cable harness, axes 5-6

The procedure below details how to inspect the cable harness of axes 5-6.

Action Note

1

DANGER

Turn off all:








157


3 Maintenance


Continued

2

3

4

Action Note

Make an overall visual inspection of the cable harness, in order to detect wear and damage.

Check the attachments at the rear of the upper arm and in the upper arm tube.

Check the connectors at the cable harness division.

Make sure the attachment plate is not bent or in any other way damaged.

Shown in the figure

Location of cabling axes 5-6 on page 157 .

Replace the cable harness if wear, cracks or damage is detected.

Described in section

Replacement of cable harness, axes 5-6 on page 241

!

158




3 Maintenance

3.3.10 Inspecting the information labels

3.3.10 Inspecting the information labels

Location of labels

These figures show the location of the information labels to be inspected. The symbols are described in section


xx0200000236

-

J

I

D

A

B

C

Warning label concerning high temperature (4 pcs)

Warning label, symbol of a flash (located on motor cover) (5 pcs)

Instruction label

Warning label concerning brake release

Warning label, tools are not allowed around the balancing device during operation

Warning label concerning shutting off power

Information labels at gearboxes and at robot base, if gearboxes are filled with

Kyodo Yushi TMO 150





159

3 Maintenance

3.3.10 Inspecting the information labels


G

H

E

F

Instruction label concerning lifting the robot

Warning label concerning risk of tipping

Foundry logotype

Warning label concerning stored energy

Required tools and equipment

Visual inspection, no tools are required.

Inspecting, labels

Action Note

1

DANGER

Turn off all:




2

3

Inspect the labels, located as shown in the figures.

Replace any missing or damaged labels.

Article numbers for the labels and plate set is specified in


160




3 Maintenance

3.3.11 Inspecting the axis-1 mechanical stop pin

3.3.11 Inspecting the axis-1 mechanical stop pin

WARNING

Mechanical stop pin can not be fitted onto robot if option 810-1 Electronic Position

Switch is used.

WARNING

Mechanical stop pin can not be fitted onto robot if option 561-1 Extended work range axis 1 is used.

Location of mechanical stop pin

The axis-1 mechanical stop is located as shown in the figure.

xx0200000151

A Mechanical stop pin


Visual inspection, no tools are required.





161

3 Maintenance

3.3.11 Inspecting the axis-1 mechanical stop pin

Continued

Inspecting, mechanical stop pin

Use this procedure to inspect the axis-1 mechanical stop pin.

Action Note

1

DANGER

Turn off all:




2 Inspect the axis-1 mechanical stop pin.

If the mechanical stop pin is bent or damaged, it must be replaced.

Note

The expected life of gearboxes can be reduced after collision with the mechanical stop.

3 Make sure the mechanical stop pin can move in both directions.

162




3 Maintenance

3.3.12 Inspecting the additional mechanical stops

3.3.12 Inspecting the additional mechanical stops

Location of mechanical stops

The figure shows the location of the additional mechanical stops on axes 1, 2 and

3 (IRB 7600 shown).

xx0200000150

A

B

Additional stop

Fixed stop





163

3 Maintenance



A

B

Additional mechanical stop

Stop pin


Equipment etc.

Mechanical stop axis 1



Article number

3HAC11076-1

3HAC11076-2

3HAC13787-1

Mechanical stop set axis 3 3HAC13128-1

Standard toolkit -

Note

Limits the robot working range by 7.5°.

Limits the robot working range by 15°.

Includes:

• Mechanical stop

• Attachment screw and washer

• Document for mechanical stop

Includes:

• Mechanical stop

• Attachment screw and washer

• Document for mechanical stop



.


164




3 Maintenance


Continued

Inspecting, mechanical stops

Use this procedure to inspect the additional mechanical stops.

Action Note

1

DANGER

Turn off all:




2

3

4

Make sure no additional stops are damaged.

Shown in figure

Location of mechanical stops on page 163 .

Make sure the stops are properly attached.

Correct tightening torque, additional mechanical stops:

• Axis 1 = 120 Nm.

• Axes 2 and 3 = 115 Nm

If any damage is detected, the mechanical stops must be replaced.

Correct attachment screws:

• Axis 1: M16 x 35, quality 12.9.

• Axis 2: M16 x 50

• Axis 3: M16 x 60






165

3 Maintenance

3.3.13 Inspecting the damper on axes 2-5

3.3.13 Inspecting the damper on axes 2-5

Location of dampers

The figure below shows the location of all the dampers to be inspected.

xx0400001024

C

D

A

B

Damper, axis 2 (2 pcs)


Damper, axis 4 (1 pc)



A damper must be replaced if damaged!

Equipment

Damper axis 2

Damper axis 3

Damper axis 4

Standard toolkit

Spare part/ art. no.

3HAC12991-1

3HAC12320-1

3HAC13564-1

3HAC15571-1

Note







3 Maintenance

3.3.13 Inspecting the damper on axes 2-5

Continued

Inspection, dampers

The procedure below details how to inspect the dampers, axes 2-5.

Action Note

1

DANGER

Turn off all:





2

3

4

Check all dampers for damage, and for cracks or existing impressions larger than 1 mm.

To inspect the damper axis 4, remove the two covers on top of the upper arm!

Shown in the figure

Location of dampers on page 166 .

Check attachment screws for deformation.

If any damage is detected, the damper must be replaced with a new one!



.




167

3 Maintenance

3.3.14 Inspection, position switch axes 1, 2 and 3

3.3.14 Inspection, position switch axes 1, 2 and 3

Position switches, axes 1-3

The position switches are shown, fitted to the robot, in section



Equipment, etc.

Position switch, axes 1-3

Standard toolkit -

-

Art. no.

Note

The article numbers of the position switches are specified in section


The contents are defined in section


in part 2 of the Product manual.



Inspection, position switches

The procedure below details how to inspect the position switch, axes 1, 2 and 3.

See the figures in section


to locate the different components to be inspected.

Action Note

1

DANGER

Turn off all:





2

3

4

Check the position switch!

• Check that the rollers are easy to push in and that they roll freely.

Check the rail!

• Check that the rail is firmly attached with the attachment screws.

Check the cams!

• Check that the rollers have not caused any impressions on the cams.

• Check that the cams are clean. Wipe them if necessary!

• Check that the set screws holding the cams in position are firmly attached.


168




3 Maintenance

3.3.14 Inspection, position switch axes 1, 2 and 3

Continued

5

6

Action Note

Check the protection sheets on axis 1!

• Check that the three sheets are in position and not damaged. Deformation can result in rubbing against the cams!

• Check that the area inside of the sheets is clean enough not to interfere the function of the position switch.

If any damage is detected, the position switch must be replaced!



!




169

3 Maintenance

3.3.15 Inspecting, signal lamp

3.3.15 Inspecting, signal lamp

Location of signal lamp

The signal lamp is located as shown in figure below. Note that the position can differ depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on the current harness for alternative positioning.

xx0200000240

C

D

A

B

E

Signal lamp

Clamp

Position for cable gland

Warning label on motor cover

Warning sign on motor cover


Equipment, etc.

Signal lamp

Standard toolkit


-

Art. no.

3HAC10830-1


170


Note

To be replaced in case of detected damage.



.




3 Maintenance

3.3.15 Inspecting, signal lamp

Continued

Inspecting, signal lamp

Use this procedure to inspect the function of the signal lamp.

1

Action

Check that signal lamp is lit when motors are put in operation ("MOTORS ON").

Note

2

DANGER

Turn off all:





3 If the lamp is not lit, trace the fault by:

• Checking whether the signal lamp is broken.

If so, replace it.

• Checking cable connections.

• Measuring the voltage in connectors motor axis 3 (=24V).

• Checking the cabling. Replace cabling if a fault is detected.



.




171

3 Maintenance

3.4.1 Type of lubrication in gearboxes

3.4 Replacement/changing activities

3.4.1 Type of lubrication in gearboxes

Introduction

This section describes where to find information about the type of lubrication , article number and the amount of lubrication in the specific gearbox. It also describes the equipment needed when working with lubrication.

Type and amount of oil in gearboxes

Information about the type of lubrication , article number as well as the amount in the specific gearbox can be found in Technical reference manual - Lubrication in gearboxes available for registered users on myABB Business Portal, www.myportal.abb.com

.

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. A new revision will be published on ABB Library immediately after updates.

Location of gearboxes

The figure shows the location of the gearboxes.

xx0800000247

D


172

A

B

C

Axis 1 gearbox

Axis 2 gearbox

Axis 3 gearbox

Axis 4 gearbox




Equipment

3 Maintenance

3.4.1 Type of lubrication in gearboxes

Continued

E

F

Axis 5 gearbox

Axis 6 gearbox

Equipment

Oil dispenser

Nipple for quick connect fitting, with o-ring

Note

Includes pump with outlet pipe.

Use the suggested dispenser or a similar one:

• Orion OriCan article number 22590

(pneumatic)




173

3 Maintenance

3.4.2 Changing oil, axis-1 gearbox

3.4.2 Changing oil, axis-1 gearbox

Location of oil plugs

The axis-1 gearbox is located between the frame and base. See oil plugs in the following figure.

trueThe oil is drained through a hose, which is located at the rear of the robot base.

xx0300000583

A

B

Oil plug, inspection

Oil plug, filling


Equipment, etc.

Lubricating oil

Oil collecting vessel

Oil exchange equipment

Art. no.

See


.

-

3HAC021745-001

Amount Note

See


.

Note


Capacity: 8,000 ml.



.





3 Maintenance


Continued

Equipment, etc.

Standard toolkit -

Art. no.

Amount Note



Draining oil, axis-1 gearbox

Use this procedure to drain the oil in gearbox axis 1.

When using oil exchange equipment, follow the instructions enclosed with the kit.

Art. no. for the kit is specified in


Action Note

1

DANGER

Turn off all:




2

WARNING



3

4

Remove rear cover on the base by unscrewing its attachment screws.

Pull out the draining hose from the rear of the base.

5 Place an oil vessel close to hose end.

6 Remove oil plug, filling in order to drain oil quicker!

xx0200000237

The hose is located beneath the base, seen from below.

A Oil draining hose

Vessel capacity is specified in


.

Shown in figure

Location of oil plugs on page 174 .





175

3 Maintenance


Continued

7

Action

Open the hose end and drain the oil into a vessel.

Note

Note

CAUTION

Drain as much oil as possible. See


.

Draining is time-consuming. Elapsed time depends on the temperature of the oil.

8

9

Close the oil drain hose, and put it back inside the base.

Refit rear cover by securing it with its attachment screws.

Filling oil, axis-1 gearbox

Use this procedure to fill gearbox axis 1 with oil.

Action

1

DANGER

Turn off all:




Note

2

WARNING




.

3

4

Open the oil plug, filling.

Shown in figure

Location of oil plugs on page 174

.

Refill the gearbox with clean lubricating oil.

The correct oil level is detailed in section


.



.

5

WARNING


6 Refit the oil plug, filling.


176




3 Maintenance



Location of oil plugs

The axis-2 gearbox is located in the lower arm rotational center, underneath the motor attachment.

xx0300000631

A

B

C

Oil plug, filling

Oil plug, draining

Vent hole


Equipment, etc.

Lubricating oil

Art. no.

See


Oil collecting vessel -


3HAC021745-001

Standard toolkit -

Amount

See


Note

Note!

Do not mix with other oil types!

Capacity: 6,000 ml.



.







177

3 Maintenance


Continued

Draining, oil

The procedure below details how to drain the oil in gearbox axis 2.

When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in


Action Note

1

DANGER

Turn off all:





2

WARNING



3

4

5

Remove the plug of the filling/inspection hole .

Shown in the figure


Remove the oil plug, draining, and drain the gearbox oil using a hose with nipple and an oil collecting vessel.

Shown in the figure




.

CAUTION

Note


Safety risks during work with gearbox lubricants

(oil or grease) on page 40

.

Draining is time-consuming. Elapsed time varies depending on the temperature of the oil.

Refit the oil plug.


Filling, oil

Use this procedure to fill oil into the axis-2 gearbox.



Action Note

1

DANGER

Turn off all:









3 Maintenance


Continued

Action Note

2

WARNING




3

4

Remove the oil plug for filling and the plug from the vent hole.

Shown in the figure

Location of oil plugs on page 177

.




.



5

WARNING


6 Refit the oil plug and the plug in the vent hole.





179

3 Maintenance




The axis-3 gearbox is located in the upper arm rotational center as shown in the following figure.

xx0200000230

A

B

C

Gearbox axis 3

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See


.

Oil exchange equipment 3HAC021745-001


Amount Note

See


Note!

Do not mix with other oil types!



.

Capacity: 3,000 ml.





Draining, oil

Equipment, etc.

Standard toolkit -

Art. no.

3 Maintenance


Continued

Amount Note



The procedure below details how to drain oil from the gearbox, axis 3.



Action Note

1

DANGER

Turn off all:





2

WARNING



.

3

4

5

Remove the oil plug, filling .

Remove the oil plug, draining, and drain the gearbox oil using a hose with nipple and an oil collecting vessel.

Shown in the figure




.

CAUTION

Note



Draining is time-consuming. Elapsed time varies depending on the temperature of the oil.

Refit the oil plug.






181

3 Maintenance


Continued

Filling, oil

The procedure below details how to fill oil into the gearbox, axis 3.



Action Note

1

DANGER

Turn off all:





2

WARNING




.

3

4

Remove the oil plug, filling.

Shown in the figure


.




.



5

WARNING


6

Note

Do not mix Kyodo Yushi TMO 150 with other oil types!

7 Refit the oil plug.


182




3 Maintenance




The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below.

xx0200000231

A

B

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See


.



Standard toolkit

-

-

Amount

See


.

Note



.

Capacity: 9,000 ml.



.

Draining, oil

The procedure below details how to drain the oil in the gearbox, axis 4.



Note

1

Action

Run the upper arm -45° from the calibration position.




183


3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:





3

WARNING



4

5

6

7


Drain the oil from the gearbox into a vessel by opening the oil plug, draining.

Shown in the figure




.

Run the upper arm back to its calibration position (horizontal position).



.

Refit the oil plug, draining.


Filling, oil

The procedure below details how to fill the oil in the gearbox, axis 4.



Action Note

1

DANGER

Turn off all:





2

WARNING







3 Maintenance


Continued

3

Action




.

Note

Shown in the figure


.



4

5

WARNING


Refit the oil plug, filling.





185

3 Maintenance




The axis 5 gearbox is located in the wrist unit as shown in the figure below.

xx0200000232

-

A

B

Wrist unit of IRB 6600 and IRB 6650

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See




Standard toolkit

-

-

Amount

See


Note


Special tools on page 436 .

Capacity: 7,000 ml.



Draining, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.



Note

1

Action

Run axis 4 to a position where the oil plug for draining is facing downwards.


186




3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:





3

4

5

6

WARNING




.


Drain the oil from the gearbox by opening the oil plug, draining.

Shown in the figure


.



Refit the oil plug, draining.


Filling, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.



1

Action

Run axis 4 to a position where the oil plug, filling, is facing upwards.

Note

2

WARNING




.

3

DANGER

Turn off all:









187

3 Maintenance


Continued

4

Action Note




Shown in the figure


.



5

6

WARNING


Refit the oil plug, filling.


188




3 Maintenance




The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.

xx0400001092

-

A

B

C

The figure above shows the wrist unit .

Gearbox, axis 6

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See



3HAC021745-001


Standard toolkit -

Amount

See


.

Note

Note




.

Vessel capacity:

500 ml







189

3 Maintenance


Continued

Draining, oil, axis 6

The procedure below details how to drain oil from the gearbox, axis 6.



1

Action

Run the robot to a position where the oil plug, filling of axis 6 gearbox is facing downwards.

Note

Shown in the figure


2

DANGER

Turn off all:





3

WARNING




.

4

5

Drain the oil from the gearbox into a vessel by removing the oil plug.

Measure the amount of oil drained.

Refit the oil plug, draining .



.

The amount of oil to be refilled depends on the amount previously drained.


Filling, oil, axis 6

The procedure below details how to fill oil into the gearbox, axis 6.



Action Note

1

DANGER

Turn off all:






190




3 Maintenance


Continued

Action Note

2

3

4

WARNING




.

Remove the oil plug, filling.

Shown in the figure


.




.



5

6

WARNING


Refit the oil plug.

Inspect the oil level.







191

3 Maintenance

3.4.8 Replacing the SMB battery

3.4.8 Replacing the SMB battery

Note

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

For a SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or

RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.

For a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended for longer production breaks with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions.

WARNING

See instructions for batteries,

Safety risks during handling of batteries on page 39

.

Location of SMB battery

The SMB battery (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure.

Battery pack with a 2-pole battery contact (DSQC) xx0300000559

A

B

C


192

SMB Battery cover

SMB battery pack with 2-pole battery contact.

Battery cable




Battery pack with a 3-pole battery contact (RMU)

3 Maintenance


Continued

A xx1400002574

E

F

G

A

B

C

D

B C

Battery pack RMU

Holder for battery

SMB cover

Battery cable

Battry holder

Guide pin (2 pcs)

SMB unit

D E F G


Note

There are two variants of SMB units and batteries. One with 2-pole battery contact

(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole battery contact has longer lifetime for the battery.

It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not exchange battery contacts!

Equipment, etc.

Battery unit

Standard toolkit -

Spare part no.

For spare part no.

see:

•


Note

Battery includes protection circuits. Only replace with a specified spare part or an ABBapproved equivalent.






193


3 Maintenance


Continued

Equipment, etc.

Circuit diagram -

Spare part no.

Note

See chapter


.

Removing, battery

Use this procedure to remove the SMB battery.

1

Action


Note

This is done in order to facilitate updating of the revolution counter.

2

DANGER

Turn off all:




3

ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit please read the safety information in the section

The unit is sensitive to ESD on page 35

4 Remove the SMB battery cover by unscrewing the attachment screws.

Shown in figure

Location of SMB battery on page 192 .

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards which can result in hazardous failures.

5

6

Pull out the battery and disconnect the battery cable .

Remove the SMB battery.

Battery includes protection circuits. Only replace with a specified spare part or with an ABB- approved equivalent.

Shown in figure


Shown in figure


Refitting, battery

Use this procedure to refit the SMB battery.

Action

1

DANGER

Turn off all:





194


Note



3 Maintenance


Continued

Action Note

2

3


The unit is sensitive to ESD. Before handling the unit please read the safety information in the section


Reconnect the battery cable and install the battery pack into the SMB/battery recess.



Note

Shown in figure

Location of SMB battery on page 192

.

C

RMU batteries are installed together with a battery holder to be properly secured inside the recess.

See figure.

Strap the battery cable to the holder.

4

5

A

D xx1300000307

A Battery pack RMU

B Battery holder

C Battery cable

D Strap

B

Secure the SMB battery cover with its attachment screws.

Shown in figure

Location of SMB battery on page 192

.

Update the revolution counters.

Detailed in chapter Calibration section

Updating revolution counters on page 396 .

6

DANGER






195

3 Maintenance

3.5.1 Lubrication of spherical roller bearing, balancing device

3.5 Lubrication activities

3.5.1 Lubrication of spherical roller bearing, balancing device

Location of bearing

The spherical roller bearing is located at the front ear of the balancing device, as shown in the figure below.

Note!

The balancing device must be mounted on the robot when lubricating the bearing!

xx0400000721

C

D

A

B

Ear (spherical roller bearing located inside)

Lubrication nipple

Sealing spacer

Hole through which the shaft is pressed


196




3 Maintenance


Continued


Equipment, etc.

Grease

Lubrication nipple

Art. no.

3HAC042534-001

Note

Optimol PDO, 150 ml

M6.

Normally fitted to the link ear at delivery.

Grease pump -

Lubrication, balancing device bearing (Design 1)

The procedure below details how to lubricate the spherical roller bearing.

Action Note

1

DANGER

Turn off all:





2

3

Lubricate the spherical roller bearing through the lubrication nipple in the ear with grease.

Fill until excessive grease is forced out between the shaft and the sealing spacer.

Art. no. and amount is specified in


Shown in the figure

Location of bearing on page 196 !


Clean the area from any excessive grease and check the area once again after operation of the robot, in order to make sure there is no incorrect leakage from the o-rings.

Read more about the inspection in section Inspection, balancing device -

Check for leakage on page 152 .

Lubrication, balancing device bearing (Design 2)

The procedure below details how to lubricate the spherical roller bearing.

Action Note

1

DANGER

Turn off all:





2 Lubricate the spherical roller bearing through the lubrication nipple in the ear with grease.

Fill until excessive grease is forced out through the hole of the lower securing screw.

Art. no. and amount is specified in


Shown in the figure

Location of bearing on page 196 !





197


3 Maintenance


Continued

3

Action Note

Refit the lower securing screw and washer.

M6 x 10, washer: D=6,4/12 T=1,6


Clean the area from any excessive grease and check the area once again after operation of the robot, in order to make sure there is no incorrect leakage from the o-rings.

Read more about the inspection in section Inspection, balancing device -


198




3 Maintenance

3.6.1 Cleaning the IRB 6650S

3.6 Cleaning activities

3.6.1 Cleaning the IRB 6650S

WARNING

Turn off all electrical power supplies to the manipulator before entering its work space.

General

To secure high uptime it is important that the IRB 6650S is cleaned regularly. The frequency of cleaning depends on the environment in which the product works.

Different cleaning methods are allowed depending on the type of protection of the

IRB 6650S.

Note

Always verify the protection type of the robot before cleaning.

Oil spills

Oil spills from gearboxes

Use the following procedure if any oil spills are detected that can be suspected to originate from a gearbox.

1 Inspect that the oil level in the suspected gearbox is according to the recommendations, see

Inspection activities on page 132 .

2 Write down the oil level.

3 Inspect the oil level again after, for example, 6 months.

4 If the oil level is decreased then replace the gearbox.

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.

• Always use cleaning equipment as specified. Any other cleaning equipment may shorten the life of the robot.

• Always check that all protective covers are fitted to the robot before cleaning.

• 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.

• Do not remove any covers or other protective devices before cleaning the robot.





199

3 Maintenance


Continued

Cleaning methods

The following table defines what cleaning methods are allowed depending on the protection type.

i

Protection type

Standard

Foundry Plus

Cleaning method

Vacuum cleaner

Yes

Wipe with cloth Rinse with water

Yes

Yes. With light cleaning detergent.

Yes. It is highly recommended that the water contains a rust-prevention solution and that the manipulator is dried afterwards.

Yes. With light cleaning detergent or spirit.

Yes. It is highly recommended that the water contains a rust-prevention solution.

High pressure water or steam

No

Yes i

.

It is highly recommended that the water and steam contains rust preventive, without cleaning detergents.

Perform according to section

Cleaning with water and steam on page 200 .

Cleaning with water and steam

Instructions for rinsing with water

ABB robots with protection types Standard , Foundry Plus , Wash , or Foundry Prime can be cleaned by rinsing with water (water cleaner).

1

I

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 700 kN/m

2

(7 bar)

I

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum flow: 20 liters/min

I

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.

2

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 2500 kN/m

2

(25 bar)

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum water temperature: 80° C

Cables

Movable cables need to be able to move freely:

• Remove waste material, such as sand, dust and chips, if it prevents cable movement.

1

2

See

Cleaning methods on page 200

for exceptions.

See

Cleaning methods on page 200

for exceptions.





Cooling fans

3 Maintenance


Continued

• Clean the cables if they have a crusty surface, for example from dry release agents.

Inspect the air supply inlet of the the motor cooling fans. Clean to remove any contamination that could hinder the air supply.




201

3 Maintenance

3.7.1 Using the SIS system

3.7 Service Information System, M2000

3.7.1 Using the SIS system

General

This is a brief description of how to use the Service Information System, SIS for

M2000 robot systems. Details may be found in:

• Service Information System, SIS

• Defining the SIS input parameters

• Setting the SIS parameters

• Importing/exporting SIS data

• Reading the SIS output logs

The section is only valid for M2000 systems. For information regarding M2004 robot systems, see additional documentation, Operating manual - Service

Information System . Article number is specified in section


Basic procedure

1

2

3

4

5

6

7

Action

Determine which of the system functions you require.

Reference

These are described in

Description of

Service Information System (SIS) on page 203

.

Define what values are adequate and suitable for your application in your production environment.

Recommendations on how to define these are given in

SIS system parameters on page 206

.

Maintenance intervals recommended by

ABB are specified in section

Maintenance schedule and expected component life on page 126 .

Enter these parameters in the system.

How to do this is detailed in

Setting the

SIS parameters on page 207 .

Run the robot in normal operation.

Reset the counter if a repair is made, or if a counter for any other reason is restarted.

The TPU displays for resetting any SIS value are shown in

Description of Service

Information System (SIS) on page 203

.

When a time limit, set in the parameters, is exceeded, a message may be read on the

Tech Pendant Unit (TPU).

How to access this is detailed in

Reading the SIS output logs on page 208 .

If the log containing the message is to be available from an external PC, or if the SIS parameters are to be entered from an external PC, a set of software tools are available to build such an application.

These are described in

Exporting the SIS data on page 209

.

202




3 Maintenance

3.7.2 Description of Service Information System (SIS)

3.7.2 Description of Service Information System (SIS)

General

Supervised functions

The following counters are available:

• Calendar time counter, a general alarm based on calendar time

• Operation time counter, a general alarm based on operational time

• Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service interval




Counters are reset when maintenance has been performed.

The counter status is displayed after running the service routine for maintenance.

Status “OK” indicates that no service interval limit has been exceeded by that counter.

Calendar time

Service Information System (SIS) is a software function within the robot controller, which simplifies maintenance of the robot system. It supervises the operating time and mode of the robot, and alerts the operator when a maintenance activity is scheduled.

Maintenance is scheduled by setting the system parameters of the type SIS

Parameters, see section

Setting the SIS parameters on page 207

. All system parameters are described in User´s Guide - System Parameters .

This is a clock within the control system that keeps track of the service interval, based on calendar time.

When the calendar time limit for maintenance is reached, a message is displayed on the TPU. How to access this is detailed in section


The following information is available about the calendar time in the service routine.

Prev service

Elapsed time

Next service

Remaining time

Date when the counter was reset last time, i.e. after the last service.

Elapsed time since the counter was reset the last time.

Date when next scheduled service is planned. This date is calculated using system parameters, as detailed in section

Setting the

SIS parameters on page 207

.

Remaining time to next scheduled service date.





203

3 Maintenance


Continued

Operation time

This is a function within the control system that keeps track of the amount of time the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the operating mode.

When the operation time limit for maintenance is reached, a message is displayed on the TPU. How to access this is detailed in section


The following information is available about the operation time in the service routine.

Service interval

Elapsed time

Remaining time

The specified service interval until another service will be required.

This parameter was entered manually as detailed in section

Setting the SIS parameters on page 207 .

Operation time since the service interval was set the last time.

Remaining operation time until the time set in service interval has expired.

Gearbox

Based on measurements, torque and RPM, for example, the system calculates an expected service interval for each gearbox. When service is due, a message will be shown on the TPU. How to access this is detailed in section

Reading the SIS output logs on page 208

.

The following information is available about the joint service status in the service routine.

Joint x OK

Joint x NOK

Joint x N/A

Service status for axis x, i.e. the automatically calculated time parameter has not been exceeded.

The service interval for the axis in question has been reached.

No service time parameter calculation available.

Applies to axes 4 and 5 (IRB 6600 and IRB 7600).

The following information is available for the axis service status in the service routine.

Consumed time

Elapsed time

Remaining time

The consumed time as a percentage of the total amount of time.

Operation time for axis x since calculation began.

Remaining operation time for axis x until the service time parameter value has been reached.

Reset values

Counters may be reset at any time by running the service routine.

When resetting, the counter variables are reset. The variables are described in section

Exporting the SIS data on page 209

!

Service interval exceeded

When the service time has been exceeded for the selection made, an error message

(Service interval exceeded!) is displayed.


204




3 Maintenance


Continued

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.




205

3 Maintenance

3.7.3 SIS system parameters

3.7.3 SIS system parameters

General

This section details the system parameters that may be set with estimated values.

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.

E.g. by setting the value "20,000", the SIS will save this as the nominal time for activating the alarm, not counting the percentage described below.

Operation time warning

A percentage of the "Operation time limit" specified above.

E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an operation time "Reset" was made the last time.

Calendar time limit (service level)

The number of calendar years selected as service interval.

E.g. by setting the value "2", the SIS will save this as the nominal time for activating the alarm, not counting the percentage described below.

Calendar time warning

A percentage of the "Calendar time limit" specified above.

E.g. by setting the value "90", the SIS will alert the operator after 90% of two years, i.e. 657 days after a calendar time "Reset" was made the last time.

Gearbox warning

A percentage of the gearbox service interval as calculated by the system. E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service interval of each gearbox.

The robot system automatically detects and stores all required variables to calculate the expected service interval (estimated remaining lifetime) of each gearbox. This is done by extrapolating data from earlier operation into a function of time, using a formula including:

• input and output torque

• gearbox spindle speed

• other variables

206




3 Maintenance

3.7.4 Setting the SIS parameters

3.7.4 Setting the SIS parameters

General

If the SIS system is to function properly, a number of parameters must be set. This is detailed below.

Procedure M2000

This is an instruction of how to enter SIS parameters to the M2000 robot system.

1

2

3

4

5

Action Note

Open "System parameters" using the TPU.

Detailed in the User's Guide.

Go to "System parameters/Manipulator/types 2".

Select "0 SIS parameters" and press "Enter".

Select the required system

The parameter list is displayed.

Select the required parameters by stepping up and down through the parameter list.

Available parameters are described in section

SIS system parameters on page 206 .




207

3 Maintenance

3.7.5 Reading the SIS output logs

3.7.5 Reading the SIS output logs

General

Whenever a set condition has expired (e.g. max allowed operation time before service), a message to this effect will be shown in the Operational log.

Access to logs

How to open a log and show its contents is detailed in the User's Guide, chapter

Service .

Available messages

The following messages may be shown:

Available in:

Calendar time

Calendar time

Operation time

Operation time

Gearbox time

Gearbox time

SIS message in the log:

Meaning:

Service Message

Service is due!

X calendar days since last service.

The manually set calendar time limit has expired.

How to set the limit is detailed in section


Proceed with the required service as detailed in chapter

Repair on page 211

or chapter


depending on which type of service.

Service Message

X calendar days to next service.

Service Message

Service is due!

X production hours since last service.

X number of calendar days remain until the manually set calendar time limit expires.

How to set the value determining when the message is to be shown, is detailed in section


The manually set operation time limit has expired.

How to set the limit is detailed in section



Repair on page 211

or chapter



Service Message

X production hours to next service.

X number of operation hours remain until the manually set operation time limit expires.



Service Message

Gearbox x requires service!

The automatically calculated gearbox time limit has expired.


Repair on page 211

or chapter



Service Message

X% of the service interval has expired for gearbox x!

X percent of gearbox hours remain until the automatically calculated gearbox time limit expires.



208




3 Maintenance

3.7.6 Exporting the SIS data

3.7.6 Exporting the SIS data

General

This section describes the available variables for entering SIS parameters as well as showing any values of exceeded time limits as detected by the SIS counters.

In a M2000 robot system, the values can be read on a PC using "Webware SDK".

How to access these variables and how to perform the actual programming sequences are detailed in the robot system User's Guide.

Definitions

The table below defines the names and functions of all software variables available for communication between the SIS and an external computer.

Signal sisRestartDate sisCalendarT sisTotRunT sisRunT sisL10h_1 sisL10h_Time_1 sisL10h_2 sisL10h_Time_2 sisL10h_3 sisL10h_Time_3 sisL10h_6 sisL10h_Time_6

Unit seconds seconds Calendar time seconds Operation time seconds Operation time hours seconds hours seconds hours seconds hours hours

Counter type

Calendar time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Function

The date on which the supervision was started/reset last time.

The number of hours since start/last reset.

Total number of operation hours since the system was started. Corresponds to the operating time counter on the control cabinet.

The number of operation hours since start/last reset of the operation time counter. Corresponds to the operating time counter on the control cabinet.

Estimated life of gearbox axis 1

Operation time of gearbox axis 1










209


4 Repair

4.1 Introduction

4 Repair


Structure of this chapter

This chapter describes all repair activities recommended for the IRB 6650S and any external unit.

It is made up of separate procedures, each describing a specific repair activity.

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.


The details of the equipment required to perform a specific repair activity are listed in the respective procedures.

The details of equipment are also available in different lists in the chapter

Reference information on page 427

.


There are general safety information and specific safety information. The specific safety information describes the danger and safety risks while performing specific steps in a procedure. Make sure to read through the chapter

Safety on page 21

before commencing any service work.

Note

If the IRB 6650S is connected to power, always make sure that the IRB 6650S is connected to earth before starting any repair work.






211

4 Repair

4.2.1 Performing a leak-down test

4.2 General procedures

4.2.1 Performing a leak-down test

When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.


Equipment, etc.

Leak-down tester

Leak detection spray -

-


Performing a leak-down test

1

2

3

Action

Finish the refitting procedure of the motor or gear in question.

Note

Remove the upper oil plug on the gear and replace it with the leak-down tester.

Regulators, which are included in the leak-down test, may be required.

Use caution, apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer.

Correct value:

0.2-0.25 bar (20-25 kPa)

CAUTION

The pressure must under no circumstance be higher than 0.25 bar (20-25 kPa). Also during the time when the pressure is raised.

4

5

6

7

8

Disconnect the compressed air supply.

Wait for approximately 8-10 minutes and make sure that no pressure loss occurs.

If the compressed air is significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease may occur. This is quite normal.

If any pressure drop occurred, then localize the leak as described in step

7 .

If no pressure drop occurred, then remove the leakdown tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detection spray. Bubbles indicate a leak.

When the leak has been localized, take the necessary measures to correct the leak.

212




4 Repair

4.2.2 Mounting instructions for bearings

4.2.2 Mounting instructions for bearings

General

This section describes how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.

1

2

3

Action

To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.

Note

Ensure that the parts included in the bearing fitting are free from burrs, grinding waste, and other contamination. Cast components must be free of foundry sand.

Bearing rings, inner rings, and roller elements must not be subjected to direct impact. The roller elements must not be exposed to any stresses during the assembly work.

Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot.

In addition to those instructions, the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange.

1

Action

Tension the bearing gradually until the recommended pre-tension is achieved.

Note

Note

The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence.

2 Make sure the bearing is properly aligned as this will directly affect the durability of the bearing.

Greasing of bearings

Note

This instruction is not valid for solid oil bearings.





213

4 Repair

4.2.2 Mounting instructions for bearings

Continued

The bearings must be greased after assembly according to the following instructions:

• The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

• During operation, the bearing should be filled to 70-80% of the available volume.

• Ensure that grease is handled and stored properly to avoid contamination.

Grease the different types of bearings as following description:

• 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.

214




4 Repair

4.2.3 Mounting instructions for seals

4.2.3 Mounting instructions for seals

General

This section describes how to mount different types of seals.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below describes how to fit rotating seals.

CAUTION

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

• Keep the seal in its original wrappings or protect it well before actual mounting.

• The fitting of seals and gears must be carried out on clean workbenches.

• Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.

1

2

3

4

Action

Check the seal to ensure that:

• The seal is of the correct type (provided with cutting edge).

• There is no damage to the sealing edge (feel with a fingernail).

Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced since it may result in future leakage.

Note

Lubricate the seal with grease just before fitting. (Not too early - there is a risk of dirt and foreign particles adhering to the seal.)

Fill 2/3 of the space between the dust tongue and sealing lip with grease. The rubber coated external diameter must also be greased, unless otherwise specified.


Equipment on page 215 .

Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in leakage.

Make sure no grease left on the robot surface.





215

4 Repair

4.2.3 Mounting instructions for seals

Continued

Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.

1

2

3

4

Action

Check the flange surfaces. They must be even and free from pores.

It is easy to check flatness using a gauge on the fastened joint (without sealing compound).

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.

O-rings

The following procedure describes how to fit o-rings.

1

2

3

4

5

Action Note

Ensure that the correct o-ring size is used.

Check the o-ring for surface defects, burrs, shape accuracy, or deformation.

Check the o-ring grooves.

The grooves must be geometrically correct and should be free of pores and contamination.

Defective o-rings may not be used.

Lubricate the o-ring with grease.

Defective o-rings, including damaged or deformed o-rings, may not be used.

Tighten the screws evenly while assembling.

Make sure that no grease is left on the robot surface.

216




4 Repair

4.2.4 Cut the paint or surface on the robot before replacing parts

4.2.4 Cut the paint or surface on the robot before replacing parts

General

Follow the procedures in this section whenever breaking the paint of the robot during replacement of parts.


Equipment

Cleaning agent

Knife

Spare parts

Lint free cloth

Touch up paint Standard/Foundry

Plus, ABB Orange

3HAC037052-001

Removing

Note

Ethanol

1

Action

Cut the paint with a knife in the joint between the part that will be removed and the structure, to avoid that the paint cracks.

Description

2 Carefully grind the paint edge that is left on the structure to a smooth surface.

xx0900000121




217

4 Repair

4.2.5 The brake release buttons may be jammed after service work

4.2.5 The brake release buttons may be jammed after service work

Description

The brake release unit has push-buttons for the brake release of each axis motor.

When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting.

DANGER

If the power is turned on while a brake release button is jammed in depressed position, the affected motor brake is released. This may cause serious personal injuries and damage to the robot.

Elimination

1

2

3

To eliminate the danger after service work has been performed inside the SMB recess, follow the procedure below.

4

Action

Make sure the power is turned off.

Remove the push-button guard, if necessary.

Verify that the push-buttons of the brake release unit are working by pressing them down, one by one.

Make sure none of the buttons are jammed in the tube.

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.

218




4 Repair

4.3.1 Replacing cable harness, axes 1-6

4.3 Complete robot

4.3.1 Replacing cable harness, axes 1-6

General

Use this section to replace the cable harness that runs undivided from axis 1 to axis 6.

If the cabling has a division point at the upper arm, see:

•

Replacement of cable harness, axes 1-4 on page 232

•

Replacement of cable harness, axes 5-6 on page 241 .

Location of cable harness

The cable harness of axes 1-6 is run throughout the robot as shown in the figure below.

xx0500002176

A

B

C

Rear cover plate

Cable guide, inside the frame

Cable gland, upper arm house





219

4 Repair


Continued

D

E

Velcro straps

Cable gland, lower arm


Equipment

Cable harness axes 1-6

Gasket

Standard toolkit


Circuit diagram

-

Spare part no.

3HAC038800-001

3HAC12877-1

Note

Motor axis 6




See chapter


.

Cable brackets of the upper arm xx0500002293

A

B

C

Cable bracket, wrist unit

Cable bracket, upper arm tube

Cable attachment, rear

Removing the cable harness - upper arm

Use this procedure to remove the cable harness from the upper arm of the robot.

1

Action

In order to facilitate refitting of the cable harness, run the robot to the specified position:

• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °

• Axis 6: no significance

Note

Axes 2 and 3 may be tilted slightly to improve access.


220




4 Repair


Continued

Action

2

DANGER

Turn off all:





3 Remove the cover, wrist unit and the cover, upper arm tube .

Note xx0200000214

A Cover, wrist unit

B Cover, upper arm tube

4

Note

Axis 5 must be oriented in the correct position

(+90º) to allow the motor 6 cover to open!

5

6

Remove the cover of motor, axis 6 and disconnect all connectors beneath.

Loosen the cable bracket, wrist unit by unscrewing its attachment screws .

Two of the attachment screws are visibly located at the rear of the bracket and the third is located at the bottom of the cable bracket, in the center.

Shown in the figure

Cable brackets of the upper arm on page 220

.

7

8

9 xx0200000254

• B: Attachment screws, rear of cable bracket (2 pcs)

• C: Attachment screw, bottom of cable bracket

Pick out the cabling from motor, axis 6.

Loosen the cable bracket, upper arm tube by unscrewing the two screws on top of the tube.

Shown in the figure


.

Disconnect the two connectors (R3.FB5 and

R3.MP5) inside the tube.

Shown in the figure

Location of cable harness on page 219

.

10

11

Remove cable straps from the harness, if any.

Remove the cable attachment, rear.

Shown in the figure


.




221


4 Repair


Continued

12

13

14

15

Action

Remove the covers of motors axes 3 and 4 and disconnect all connectors beneath.

Pick out the cabling from the motors.

Note

Gently pull the cable harness out from the upper arm tube.

Tie the connectors into bundles, to avoid damaging them during further removal.

Continue removing the cable harness in lower arm, frame and base.

Removing the cable harness - frame and base

Use this procedure to remove the cable harness from the frame and base.

1

2

3

4

5

6

Action Note

Remove the rear cover plate from the robot by removing its attachment screws.

Shown in the figure


.

Disconnect the earth cable beneath the rear cover plate.

Disconnect connectors R1.MP and R1.SMB

.

Shown in the figure


.

Pull the cable and connectors up through the cable guide in the center of the frame.

Disconnect all connectors at motors 1 and 2.

Open the SMB cover carefully.

The cable between the battery and the SMBunit can stay connected, in order to avoid an update of the revolution counter. Be careful not to let the weight of the cover strain the cable!

7

Note

In order to remove the cover completely, the connector R1.G must be disconnected! This causes a necessary updating of the revolution counter!

Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.

Disconnect X8, X9 and X10 from the brake release unit.


222


xx0200000118



4 Repair


Continued

8

Action

Remove

• the cable gland , by removing the four attachment screws from inside the SMB recess

• the attachment plate , by removing the attachment screws and the velcro strap .

Note

Note

Different robot versions are fitted with different versions of the attachment plate. When replacing the cable harness, make sure the correct one is used to avoid cable failure.

9

10

Remove the cable gland securing the cables inside the lower arm.

Remove the velcro strap and cable gland.

xx0300000560

A Cable gland

B Attachment screws, cable gland

C Attachment plate

D Velcro strap





223

4 Repair


Continued

Removing the cable harness - lower arm

Use this procedure to remove the cable harness from the lower arm.

Note

1

Action

Remove the cable gland that secures the cables to the arm house.

2

3

4 xx0100000143

Remove the velcro strap from the harness at the cable fixing bracket at the arm house.

Shown in the figure


.

Disconnect all connectors at the axis-3 and axis-4 motors.

Gently pull the cable harness out.

Refitting the cable harness - lower arm, frame and base

Use this procedure to refit the cable harness on the lower arm, frame and base of the robot.

How to refit on the upper arm is described in section

Refitting the cable harness upper arm on page 229

.

1

2

Action Note

Push the cable and connectors down through the cable guide in the center of the frame.

• Make sure the cables are not twisted with each other or with customer harnesses if any

• Make a note of the correct positions of the connectors.

Shown in the figure


.

Reconnect connectors R1.MP and R1.SMB

at the base.

Tightening torque for R1.SMB: 10 Nm.

Shown in the figure


.

Make a note of the correct positions of the connectors!





4 Repair


Continued

3

4

5

Action Note

Reconnect the earth cable .

Refit the rear cover plate to the robot with its attachment screws.

Shown in the figure


.

Reconnect all connectors at motors axes 1 and

2.





225

4 Repair


Continued

6

Action

Secure the cable gland with four attachment screws from inside the SMB recess.

Secure the correct attachment plate to the cable gland with its two attachment screws, using locking liquid.

Refit the velcro strap . Shown in the figure


.

Note

Locking liquid is specified in


.

Note

Different robot versions are fitted with different versions of the attachment plate. Make sure the correct one is used to avoid cable failure.

xx0300000560

A Cable gland

B Attachment screws, cable gland

C Attachment plate

D Velcro strap


226




4 Repair


Continued

7

Action

Reconnect connectors to the SMB unit:

• R2.SMB

• R1.SMB1-3

• R1.SMB4-6

Reconnect connectors to the Brake release unit:

• X8

• X9

• X10

Reconnect R1.G if it has been disconnected.

Note

8 Secure the SMB cover with its attachment screws.

If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm.

9

WARNING

Before continuing any service work, please observe the safety information in section

The brake release buttons may be jammed after service work on page 218

!

10

11

Push the cable harness gently through the lower arm.

Refit the cable gland securing the cables inside the lower arm.

xx0200000118 xx0100000142





227

4 Repair


Continued

12

Action

Refit the cable gland securing the cables to the arm house.

Note

Note

The cable harness is delivered in a pretwisted state. Make sure not to affect this by twisting the cable harness further in any direction.

13 Fit a cable protection to the lower arm, if not already mounted, with two securing screws ,

M6x16.

Secure the cable harness with two velcro straps , with a distance of approximately 180 mm. Fix the strap by wrapping it two turns around the largest cable before wrapping around the complete harness.

xx0100000143


228


xx0500002320

Parts:

• A: Securing screws, M6x16 (2 pcs)

• B: Velcro straps (2 pcs)



4 Repair


Continued

Refitting the cable harness - upper arm

Use this procedure to refit the cable harness on the upper arm of the robot.

How to refit the cable harness on lower arm, frame and base is described in section

Refitting the cable harness - lower arm, frame and base on page 224

.

1

2

Action

Before refitting the upper end of the cable harness, the lower end must first be refitted.

Note

How to refit see section

Refitting the cable harness - lower arm, frame and base on page 224 .

Refit the cable gland securing the cables in the armhouse.

Note

The cable harness is delivered pretwisted.

Make sure not to affect this by twisting the cable harness further in any direction.

xx0100000143

3

4

5

6

Reconnect all connectors on motors axes 3 and 4.

Secure the cable harness to the upper armhouse by refitting the velcro strap to the cable bracket at the upper armhouse.

Refit the velcro strap at the guide plate axis 2.

Shown in the figure


.

Gently insert the cable harness from the rear into the upper arm.

Connect the two connectors inside the upper arm tube, R2.FB5 and R3.MP5 and secure the cable bracket with its two attachment screws to the tube.

Shown in the figure

Cable brackets of the upper arm on page 220 .

7

Note

The position of axis 6 must be +90° for a correct installation of the cable harness.





4 Repair


Continued

8

Action

Place the cabling to motor axis 6 correctly on the upper arm and gently pull the connectors through the hole on top of the wrist unit to motor axis 6.

In case of excess of cable length:

• put the excess cable in a loop in the area shown in the figure and secure with cable straps. Cables are longer in order to fit different upper arm lengths.

Note

9 Fasten the cable bracket, wrist unit with its attachment screws . Two screws are visible at the rear attachment point of the bracket and the third is located at the bottom of the cable bracket , in the center.

xx0200000185

• A: Cable straps

Note

10

11

Do not use stainless attachment screws!

There is a potential risk of galvanic corrosion.

xx0200000254

• B: Attachment screws, rear attachment point of cable bracket

(2 pcs)

• C: Attachment screw, bottom of cable bracket (1 pc)

Reconnect the connectors to motor, axis 6 and refit the motor cover.

Foundry robots:

It is recommended to use a new gasket on cover.

Refit the cover, upper arm tube and the cover, wrist unit .

Make sure the cabling is placed correctly when refitting the covers, and does not get jammed.

12

13

14 xx0200000214

Parts:

• A: Cover, wrist unit. Tightening torque: 14 Nm.

Add Loctite to screw before fastening. Screw 3HAB3409-25,

Washer 3HAC062379-001

• B: Cover, upper arm tube

If any cable straps have been removed, refit them to the harness.

Refit the cable attachment, rear.

Shown in the figure

Cable brackets of the upper arm on page 220 .

If the connection between the SMB battery and the SMB unit has been broken, the revolution counters now must be updated!

Detailed in section






4 Repair


Continued

Action

15

DANGER



Note




231

4 Repair

4.3.2 Replacement of cable harness, axes 1-4

4.3.2 Replacement of cable harness, axes 1-4

General

This section details how to replace the cable harness that runs from axis 1 to axis

4. If the robot is equipped with an undivided cable harness, it is instead replaced as detailed in section

Replacing cable harness, axes 1-6 on page 219

.

(The divided cable for axes 1-4 is not applicable for robot model IRB 6650S - 90/3.9.)

Location of cable harness

The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below.

xx0300000589

A

B

Rear cover plate

Attachment point for earth lug


232




4 Repair


Continued

F

G

H

C

D

E

K

L

I

J

M

Connector R1.MP

Connector R1.SMB

Cable guide in the center of the frame

Connectors at motor 1: R2.FB1 and R2.MP1


SMB recess

Cable gland, upper arm house

Cable fixing bracket + velcro strap

Connector R2.M5/6 at the cable division point

Connectors at motor 3: R2.FB3 and R2.MP3 (optional signal lamp: R2.H1 and

R2.H2)



Equipment, etc.


Locking liquid

Spare part no.

3HAC033389-001

Art. no.

Standard toolkit


Circuit diagram

-

Note

Loctite 243

Used to secure the attachment screws for the attachment plate inside the frame.




See chapter


.

Removal, cable harness, axes 1-4

The procedure below details how to remove the cable harness, axes 1-4.

1

Action

In order to facilitate refitting of cable harness, run the robot to the specified position:

• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °


Note






233

4 Repair


Continued

Action Note

2

DANGER

Turn off all:





3

4

5

6

7

8

9

Remove the rear cover plate from the robot by removing its attachment screws.

Shown in the figure


.

Disconnect the earth cable .

Attachment point is shown in the figure


!

Disconnect connectors R1.MP and R1.SMB

.

Attachment points are shown in the figure

Location of cable harness on page 232 .

Pull the cable and connectors up through the cable guide in the center of the frame.

Disconnect all connectors at motors 1 and 2.

Specified and shown in the figure

Location of cable harness on page 232 !

Open the SMB cover carefully.

The cable between the battery and the SMB-unit may stay connected, in order to avoid an update of the revolution counter. Be careful not to let the weight of the cover strain the cable!

In order to remove the cover completely, the connector R1.G must be disconnected! This causes a necessary updating of the revolution counter!

Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.

Disconnect X8, X9 and X10 from the brake release unit.

xx0200000118


234




4 Repair


Continued

10

Action

Remove

• the cable gland (A), by removing the four attachment screws from inside the SMB recess

(B)

• the attachment plate (C), by removing the attachment screws and the velcro strap (D).

Note

Note

Different robot versions are fitted with different versions of the attachment plate. When replacing the cable harness, make sure the correct one is used to avoid cable failure.

11 Remove the cable gland securing the cables inside the lower arm.

xx0400001069

• A: Cable gland

• B: Attachment screws, cable gland

• C: Attachment plate

• D: Velcro strap





235

4 Repair


Continued

12

Action

Remove the cable gland securing the cables to the arm house.

Note xx0100000143

13

14

15

Remove the velcro strap from the harness at the cable fixing bracket at the arm house.

Shown in the figure


.

Disconnect connector R2.M5/6 at the cable division point.

Shown in the figure


!

Disconnect all connectors at motor 3 and motor 4.



16 Gently pull the cable harness out.

Refitting, cable harness, axes 1-4

The procedure below details how to refit the cable harness, axes 1-4.

Action Note

1

DANGER

2

Turn off all:





In order to facilitate refitting of cable harness, move the robot to the specified position:

• Axis 1: 0 degrees




• Axis 5: +90 degrees







4 Repair


Continued

3

4

5

6

7

Action Note

Pull the cable and connectors down through the cable guide in the center of the frame.

Make sure the cables are not twisted with each other or with eventual customer harnesses!


Reconnect connectors R1.MP and R1.SMB

at the rear cover plate.

Tightening torque for R1.SMB: 10

Nm.



Location of cable harness on page 232 .

Reconnect the earth cable.



Refit the rear cover plate to the robot with its attachment screws.

Shown in the figure


.

Reconnect all connectors at motors 1 and 2.







237

4 Repair


Continued

8

Action Note

Secure the cable gland (A) with four attachment screws (B) from inside the SMB recess.

Secure the correct attachment plate (C) to the cable gland with its two attachment screws, using locking liquid.

Refit the velcro strap (D).



.

Note

Different robot versions are fitted with different versions of the attachment plate. Make sure the correct one is used to avoid cable failure.

9

10

Reconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 to the SMB unit.

Reconnect X8, X9 and X10 to the brake release unit.

Reconnect R1.G if it has been disconnected.

Secure the SMB cover with its attachment screws.

If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm.


238 xx0400001069

• A: Cable gland

• B: Attachment screws, cable gland

• C: Attachment plate

• D: Velcro strap




4 Repair


Continued

Action

11

WARNING

Before continuing any service work, please observe the safety information in section

The brake release buttons may be jammed after service work on page 218 !

Note

12

13

Pull the cable harness through the lower arm.

Refit the cable gland securing the cables inside the lower arm.

14 Refit the cable gland securing the cables to the arm house.

Make sure not to twist the harness!

xx0100000142 xx0100000143

15

16

17

Reconnect all connectors at motor 3 and motor

4.



Reconnect the connector R2.M5/6 gently at the cable division point.

Be careful not to bend the attachment plate when fastening the screws!

Shown in the figure


!

M6, 2 pcs.

Secure the cable harness to the upper arm house by refitting the velcro strap to the cable bracket at the upper arm house.

Shown in the figure


!





239

4 Repair


Continued

18

Action Note

Fit a cable protection to the lower arm, if not already mounted, with two securing screws (A),

M6x16.

Secure the cable harness with two velcro straps

(B), with a distance of approximately 180 mm. Fix the strap by wrapping it two turns around the largest cable before wrapping around the complete harness.

Both the protection and the strap are included in the spare part no., specified in


xx0500002320

19

20

21

Refit the cable harness to the guide plate axis 2 .

Shown in the figure


.

Refit the velcro strap at the guide plate axis 2.

Shown in the figure


.

If the connection between the SMB battery and the SMB unit has been broken, the revolution counters must now be updated!

Detailed in the Calibration chapter

- section


22

DANGER



240




4 Repair


4.3.3 Replacement of cable harness, axes 5-6

General

This cable is not applicable for robot model IRB 6650S - 90/3.9.

Location of cable harness ax 5-6

The location of the cable harness, axes 5-6, is shown in the figure below.

xx0200000213

G

H

D

F

A

B

C

Cable bracket, wrist unit

Cable bracket, upper arm tube

Connectors at motor axis 5; R4.FB5 and R4.MP5

Connectors in upper arm tube; R3.FB5 and R3.MP5

Cable attachment, rear

Connector at cable harness division point; R2.M5/6

Connectors at motor, axis 6; R3.FB6 and R3.MP6





241

4 Repair


Continued


Equipment, etc.


Standard toolkit -

Spare part no.

3HAC14140-1

Note

Not applicable for IRB 6650S - 90/3.9.





Circuit diagram See chapter


.

Removal, cable harness, axes 5-6

The procedure below details how to remove the upper cable harness.

The separate cable that goes from the connection point inside of the upper arm tube to the motor, axis 5, is not included in this procedure. The removal of that cable is described in section

Removal, cabling axis 5 motor on page 246 .

Action Note/Illustration

1

DANGER

Turn off all:





2 Remove the cover, wrist unit and the cover, upper arm tube.

xx0200000214

• A: cover, wrist unit

• B: cover, upper arm tube

3

Note



4 Remove the cover of motor, axis 6 and disconnect all connectors beneath.

Specified in the figure

Location of cable harness ax 5-6 on page 241

.


242




4 Repair


Continued

5


Loosen the cable bracket on top of the wrist unit by undoing the three attachment screws.

Two of the attachment screws are visibly located at the rear attachment and the third is located at the bottom of the cable bracket, in the center.

Shown in the figure

Location of cable harness ax 5-6 on page 241 .

6

7

8

9

10 xx0200000254

• B: Attachment screws, rear of cable bracket, 2 pcs

• C: Attachment screw, bottom of cable bracket, 1 pc

Pick out the cabling from motor, axis 6.

Loosen the cable bracket in the upper arm tube by undoing the two screws on top of the tube.

Shown in the figure


Disconnect the two

R3.MP5) in the tube.

connectors (R3.FB5 and

Remove eventual cable straps from the harness.

Remove the cable attachment, rear.

Shown in the figure


11

12

Disconnect connector R2.M5/6 at the cable harness division point.

Gently pull the cable harness out.

Shown in the figure


Shown in the figure


Refitting, cable harness, axes 5-6

The procedure below details how to refit the upper arm cable harness. The separate cable that goes from the connection point inside of the upper arm tube to the motor, axis 5, is not included in this procedure. The refitting of that cable is described further down in section

Refitting, cabling axis 5 motor on page 247 .

1

2

3

Action

Position the upper arm as follows:


• Axis 5: +90 degrees


Gently insert the cable harness from the rear into the upper arm.


Connect the two connectors inside the upper arm tube, R3.FB5 and R3.MP5

and secure the cable bracket with the two attachment screws to the tube.

Shown in the figure






243

4 Repair


Continued

4

Action

Place the cabling to motor, axis 6, correctly on the upper arm and gently pull the connectors through the hole on top of wrist unit to motor, axis 6.


5 xx0200000185

• In case of excess cable length: put a loop of cable in this area with cable straps (A). The cables are longer in order to fit different upper arm lengths.

Fasten the cable bracket, wrist unit with three attachment screws, two of them visible at the rear attachment point and the third located on the bottom of the cable bracket, in the center.

Also shown in the figure


6

7

Reconnect the connectors to motor, axis 6 and refit the motor cover.

Refit the cover, upper arm and the cover, wrist unit.

Make sure the cabling is placed correctly when refitting the covers, and does not get jammed.

xx0200000254

• B: Attachment screws, rear of cable bracket.

• C: Attachment screw, bottom of cable bracket.

8

9

10 xx0200000214

• A: Cover, wrist unit. Tightening torque: 14 Nm.

Add Loctite to screw before fastening. Screw 3HAB3409-25,

Washer 3HAC062379-001

• B: cover, upper arm tube

If any cable straps have been removed, refit them to the harness.

Refit the cable attachment, rear.

Shown in the figure


Reconnect connector R2.M5/6 gently at the rear cable division point with two screws, M6.


Shown in the figure






11

Action

Update the revolution counter!

4 Repair


Continued


Detailed in section





245

4 Repair

4.3.4 Replacement of cabling, axis 5 motor

4.3.4 Replacement of cabling, axis 5 motor

Location of cabling

The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in the figure below.

xx0500002294

A

B

Motor axis 5 with connectors R4.FB5 and R4.MP5

Connectors R3.FB5 and R3.MP5


Equipment

Cable harness axis 5

Circuit diagram

Standard toolkit


Spare part no.

See


.

Note

3HAC025744-001



.


Removal, cabling axis 5 motor

The procedure below details how to remove the cabling from the axis 5 motor.

Action Note

1

DANGER

Turn off all:





2 Remove the complete wrist unit.

Detailed in section:

•

Removal, wrist unit on page 260 .





4 Repair

4.3.4 Replacement of cabling, axis 5 motor

Continued

3

4

5

6

Action

Remove the cover of motor, axis 5.

Disconnect all connectors at motor, axis 5.

Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

Remove the cable, axis 5.

Note

Refitting, cabling axis 5 motor

The procedure below details how to refit the cabling to the motor of axis 5.

Action Note

1

DANGER

4

5

2

3

6

Turn off all:





Reconnect all connectors at motor, axis 5.

Refit the cable gland cover at the cable exit with its two attachment screws.

Refit the cover of motor, axis 5.

Refit the complete wrist unit.

Re-calibrate the robot.

Detailed in section:

•

Refitting, wrist unit on page 261 .

Calibration is detailed in a separate calibration manual enclosed with the calibration tools.

General calibration information is included in section


.

7

DANGER






247

4 Repair

4.3.5 Replacement of complete arm system

4.3.5 Replacement of complete arm system

Location of arm system

The complete arm system is defined as the complete robot except for the base and axis-1 gearbox. This is shown in the figure below.

A more detailed view of the component and its position may be found in


xx0300000465

A

B

C

D

E

F


248

Upper arm

Lower arm

Frame

Gearbox, axis 1

Base attachment screws

Balancing device




4 Repair


Continued

G

H

Block for calibration

Motor axis 1


Equipment, etc.


Guide pins M12 x 130

Roundsling 1,5 m

Hoisting block

Isopropanol

Standard toolkit


-

-

-

Art. no.

3HAC15607-1

3HAC022637-001

Note

Instruction 3HAC15971-2 is enclosed!

Used to guide the complete arm system when lifting it.

Always use the guide pins in pairs!

In order to make the refitting easier, it is recommended to use two guide pins of different lengths. Notice that longer guide pins than 140 mm will not be possible to remove from the frame because lack of space after refitting!

Lifting capacity 1,000 kg

Used to adjust the length of the lifting chain.

Used for cleaning mounting surfaces.



.


Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.

Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table.

1

Action Note

Decide which calibration routine to use for calibrating the robot.

• Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot.

• Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot.

If the robot is to be calibrated with reference calibration:

Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values.

Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot.

If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible.

Creating new values requires possibility to move the robot.

Read more about reference calibration for

Axis Calibration in

Reference calibration routine on page 402

.


Pendulum Calibration in Operating manual - Calibration Pendulum .




249


4 Repair


Continued

Action

If the robot is to be calibrated with fine calibration:

Remove all external cable packages

(DressPack) and tools from the robot.

Note

Removal, arm system

Use this procedure to lift and remove the complete arm system.

1

2

Action

Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.

Note

Run the robot to the position shown in the figure to the right.

Release the brakes if necessary, as detailed in section


xx0300000632

3

4

Run the overhead crane to a position above the robot.

Fit the lifting accessory and adjust it as detailed in the enclosed instructions .



Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting accessory!

Read the instructions before lifting!

5

DANGER

Turn off all:





6 Drain the oil from gearbox axis

1.

Detailed in section


.


250




4 Repair


Continued

7

8

Action

Remove the motor, axis 1.

Note

Disconnect the cabling in the rear of the robot base and remove the cable support plate inside the base.

Pull the disconnected cabling up through the center of the axis-1 gearbox.

How to replace the cabling is detailed in


.

Detailed in section

Removal, motor axis 1 on page 322 .

9

10 Remove the block for calibration from the bottom of the frame.

Shown in the figure

Location of arm system on page 248

.

11 Unfasten the arm system from the base by unscrewing its 24 attachment screws.

Shown in the figure

Location of arm system on page 248

.

xx0600003070

Parts:

• A: Serrated lock washer

• B: Gearbox axis 1

• C: Attachment screws M12x110

12 Fit two guide pins in two opposite screw holes.



.

13

CAUTION

The complete arm system weighs 1250 kg! All lifting equipment used must be sized accordingly!

14 Lift the arm system carefully and secure it in a safe area.

Always move the robot at very low speeds, making sure it does not tip.

Continue lifting even if the arm system turns out to be unbalanced despite earlier adjustments! The risk of damaging the interfaces is bigger if the load is lowered unbalanced!

Make sure all hooks and attachments stay in the correct position while lifting the arm system and that the lifting accessory does not wear against sharp edges.





251

4 Repair


Continued

Refitting, arm system

The procedure describes how to lift and refit the complete arm system.

Action Note

1

DANGER

Turn off all:





2 Fit the lifting accessory as detailed in enclosed instruction.

Also fit a hoisting block to the front chain.

(Used to adjust the balance of the arm system in order to lift it completely level!)



Make sure the lift is done completely level!

How to adjust the lift is described in the enclosed instruction to the lifting accessory!

Follow the instructions before lifting!

Releasing the brakes are detailed in section


3

CAUTION

The complete arm system weighs 1250 kg!

All lifting equipment used must be sized accordingly!

4

5

6

Lift the complete arm system and move it at very low speed, making sure it does not tip!

Make sure the lift is done completely level.

Adjust the length of the chains as detailed in enclosed instruction or with a hoisting block.

Clean the mounting surfaces with isopropanol.

Fit the two guide pins to the frame attachment holes, as shown in the figure to the right.

Fit one guide pin next to the guiding hole

(for the spring pin in the gearbox) and the other guide pin straight across the frame.

Dimension is specified in


.

Note

Lubricate the guide pins for easier fitting of the arm system.

xx0600003441

The figure above shows the frame, view from below.

A Attachment holes for the guide pins, M12.

B Guiding hole for the spring pin located in the gearbox, axis 1.





4 Repair


Continued

7

8

Action Note

Lubricate the outer surface of the gearbox for easier mating of the gearbox and arm system.

Look through the empty mounting hole of motor 1 to assist in aligning the assembly during refitting of the arm system.

The spring pin in the gearbox must be fitted to the guiding hole of the frame (B).

Lower the arm system with guidance from the guide pins previously fitted to the frame.

This is a complex task to be performed with utmost care in order to avoid injury or damage!

Note

The refitting must be made completely level!

Make sure the lifting accessory is adjusted prior to refitting of arm system.

9 Refit 22 of the 24 attachment screws before the arm system is completely lowered.

10 Remove the guide pins and secure the arm system to the base with its 24 attachment screws and washers.

Shown in the figure

Location of arm system on page 248 .

M12 x 110, 12.9 quality UNBRAKO.


Reused screws may be used, providing they are lubricated as detailed in section

Screw joints on page 431

before fitting.

11 Refit the block for calibration at the bottom of the frame.

Shown in the figure

Location of arm system on page 248 .

12 Refit the axis-1 motor .

Detailed in section

Refitting, motor axis 1 on page 323 .

13 Perform a leak-down test of the axis-1 gearbox.

14 Refit the cabling in the base.

15 Refill the gearbox with lubricating oil.

Detailed in section

Performing a leakdown test on page 212

.

16 Recalibrate the robot.

Detailed in section


.

Pendulum Calibration is described in Operating manual - Calibration Pendulum , enclosed with the calibration tools.

Axis Calibration is described in

Calibrating with Axis Calibration method on page 401 .


Calibration on page 389 .

17

DANGER






4 Repair

4.4.1 Replacing the turning disk

4.4 Upper and lower arm

4.4.1 Replacing the turning disk

Location of turning disk

The turning disk is located in the front of the wrist housing as shown in the figure below.

xx0200000217

C

D

F

A

B

Turning disk

Wrist unit

Oil plug, draining

Oil plug, filling

Attachment screws (12 pcs)


Equipment, etc.

Turning disk

Art. no.

For spare part no.

see:


Note

O-ring

Wrist, type 2

Grease

Flange sealant

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.

-

3HAB3772-64 (1 pc)

3HAB3772-61 (12 pcs)

Must be replaced when replacing the turning disk!

3HAB3537-1

3HAC034903-001

Used to lubricate the o-rings.

Loctite 574



.



254




4 Repair


Continued

Removing, turning disk

Use this procedure to remove the turning disk.

1

Action Note

Run the robot to a position where the oil plug, draining of axis 6 gearbox faces downwards.

Shown in the figure

Location of turning disk on page 254

.

2

DANGER

Turn off all:




3

4

5

6

7

Remove any equipment fitted to the turning disk.

Drain the axis 6 gearbox.

See section

•


Remove the attachment screws that secure the turning disk.

Remove the turning disk .

Foundry Plus:

Remove old flange sealant residues and other contamination from the contact surfaces.

Shown in the figure

Location of turning disk on page 254

.





255

4 Repair


Continued

Refitting, turning disk

Use this procedure to refit the turning disk.

1

Action Note

Lubricate the o-ring of the turning disk with grease and fit it to the turning disk.

Also fit the 12 o-rings, when refitting the attachment screws.



.

2 Foundry Plus:

Apply Loctite 574 flange sealant on the contact surface.

xx0200000218

• A: Sealing surface, o-ring xx1400000995

3

4

5

6

Secure the turning disk with its screws .

attachment

Perform a leak-down test of the gearbox axis

6.

Refill the axis 6 gearbox with oil.

12 pcs, M12 x 30, 12.9 quality Gleitmo.

Tightening torque: 100 Nm.



before fitting.


Performing a leak-down test on page 212

.

See section

•


Refit any equipment removed during disassembly to the turning disk.





Action

7

DANGER



Note

4 Repair


Continued




257

4 Repair

4.4.2 Replacement of complete wrist unit

4.4.2 Replacement of complete wrist unit

Location of wrist unit

The wrist unit is located on the upper arm as shown in the figure below.



xx0200000184

E

F

C

D

G

I

H

A

B

Wrist unit

Turning disk

Cover, wrist unit

Cover, upper arm tube

Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)

Cable bracket

Attachment point for lifting tool, wrist unit

Wrist unit attachment screws and washers

Upper arm tube


258




4 Repair


Continued


Equipment etc.

Wrist unit

Cover for wrist unit


Lifting accessory, wrist unit

Standard toolkit


Circuit diagram

Art. no.

For spare part number, see


.

Note



.

-

3HAC13056-3

3HAC13605-1

Always use guide pins in pairs!




See chapter

page 441 .

Circuit diagram on




1

Action Note










Axis Calibration in


.










259

4 Repair


Continued

Removal, wrist unit

2

3

The procedure below details how to remove the complete wrist unit.

1

Action


Note

Remove all equipment fitted to the turning disk.

Turn axis 4 to a position where the cover, upper arm tube and wrist unit, faces upwards. Turn axis 5 to +90°.

xx0200000185

4

DANGER

Turn off all:





5

6

7

8

Remove the

Remove the cover, wrist unit .

cover, upper arm tube.

Shown in the figure

Location of wrist unit on page 258 .

Shown in the figure


Remove the cover of motor, axis 6 and disconnect all connectors beneath.

Loosen the cable bracket, wrist unit on top of the wrist by undoing the three attachment screws.

Two of the attachment screws are visibly located at the rear of the bracket and the third located at the bottom of the cable bracket, in the center.

Shown in the figure


xx0200000254

• B: Attachment screws, rear of cable bracket (2 pcs)


9

10

Pick out the cabling from motor, axis 6 and place it safely on the tube.

Fit the lifting accessory to the wrist unit.



.


260




4 Repair


Continued

Action

11

CAUTION

The complete wrist unit weighs 130 kg! All lifting equipment used must be sized accordingly!

Note

12

13

Slightly raise the wrist unit to unload the screw joint, facilitating removing the attachment screws.

Remove the wrist unit attachment screws and washers .

Shown in the figure


14

15

Pull the wrist unit out, lift it away and place it on a secure surface.

Disconnect the motor axis 5 by disconnecting the two connectors in the upper arm tube

(R3.FB5, R3.MP5).

Shown in the figure


Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.

Action Note

1

DANGER

2

3

Turn off all:





Fit two guide pins, M12 in the upper arm tube, in two of the holes for the wrist unit attachment screws.



.

Shown in the figure

Location of wrist unit on page 258

.

Fit the lifting tool to the wrist unit.

Art. no. is specified


.

4

5

6

CAUTION

The complete wrist unit weighs 130 kg! All lifting equipment used must be sized accordingly!

Lift the wrist unit and guide it to the upper arm tube with help of the guide pins.

Make sure the cabling from motor, axis 5 is safely run into the arm tube and does not get jammed.

Reconnect the motor axis 5 by connecting the two connectors inside the upper arm tube

(R3.FB5, R3.MP5) and secure the cable bracket with the two attachment screws to the tube.

Shown in the figure


.




261


4 Repair


Continued

7

8

9

10

Action Note

Secure the wrist unit with 10 of the 12 attachment screws and washers .

Shown in the figure


.

12 pcs: M12 x 50, 12.9 quality Gleitmo.




before fitting.

Remove the guide pins and secure the two remaining attachment screws as detailed above.

Remove the lifting tool from the wrist unit.

Note



11

12

Place the cabling to motor axis 6 correctly on the upper arm and gently pull the connectors through the hole on top of wrist unit to motor, axis 6.

In case of excess of cable length:

• put the excess cable in a loop in the area shown in the figure and secure with with cable straps . Cables are longer in order to fit different upper arm lengths.

xx0200000185

Parts:

• A: Cable straps

Fasten the cable bracket at top of the wrist unit with three attachment screws . Two of them are visible at the rear attachment point and the third is located on the bottom of the cable bracket, in the center.

Shown in the figure


.

13

14

15 xx0200000254

• B: Attachment screws, rear attachment point of cable bracket

(2 pcs)


Reconnect the connectors to the axis-6 motor and refit the motor cover.

Refit the cover, upper arm tube.

Shown in the figure


.

Refit the cover, wrist unit.

Shown in the figure


.

Tightening torque: 14 Nm±10%. Screw

3HAB3409-25 (with Loctite), Washer

3HAC062379-001.





4 Repair


Continued

16

Action

Re-calibrate the robot!

17 Refit any equipment previously removed from the turning disk.

18

DANGER


First test run may cause injury or damage on page 30

.

Note

Pendulum Calibration is described in

Operating manual - Calibration Pendulum , enclosed with the calibration tools.








263

4 Repair

4.4.3 Replacement of upper arm

4.4.3 Replacement of upper arm

Location of upper arm

The upper arm is located on top of the robot as shown in the following figure. The complete upper arm includes the wrist unit but this section also describes how to remove the upper arm when there is no wrist unit mounted.

Note

The lifting accessory is attached differently depending on whether the wrist unit is mounted on the upper arm or not. The attachment points are shown in the following figure.


264




4 Repair


Continued







265

4 Repair


Continued

C

D

E

F

G

H xx0200000163

A

B

Attachment hole for lifting eye, M12 (if wrist unit is mounted)

Attachment for lifting accessory, upper arm (2 pcs if there is no wrist unit mounted)

Oil plug, draining, gearbox axis 3

Cable harness division; connector R2.M5/6

Motor, axis 3

Motor, axis 4

Attachment screws and washers, upper arm

Sealing, axis 2/3 (between lower arm and gearbox axis 3)





4 Repair


Continued


Equipment

Sealing, axis 3

Art. no.

3HAC17212-1

Foundry Prime (grey) 3HAC038648-001

Washer, axis 3 (3 pcs)

Standard and Foundry Plus (ABB

Orange)

3HAC038648-002

3HAC038648-003 Washer, axis 3 (3 pcs)

Standard and Foundry Plus

(Graphite White)

Guide pins, sealing axis 2/3 80 mm

3HAC14628-1

Guide pins, sealing axis 2/3 100 mm

3HAC14628-2

Power supply -

Note

Always use a new sealing when refitting the upper arm!

To be replaced if damaged.



Rotation tool 3HAC17105-1

For guiding the axis-3 sealing.


24 VDC, max 1,5A

For releasing the brakes.

Used to rotate the motor shaft beneath the motor cover, when brakes are released with 24 VDC power supply.

Lifting eye VLBG M12

Lifting accessory, upper arm

Lifting tool (chain)

3HAC16131-1

3HAC15994-1

3HAC15556-1

Standard toolkit -

To be used together with lifting eye, M12 and lifting accessory, upper arm.








1

Action




Note





267

4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, upper arm

The procedure below details how to remove the upper arm.

1

2

3

4

5

Action Note


Remove all equipment fitted to turning disk.

Move the upper arm to a horizontal position.

Rotate axis 4 so that the attachment hole for lifting eye is faced upwards!

Shown in the figure

Location of upper arm on page 264 .

Rotate axis 5 to position +90°.

DANGER

Turn off all:





6

7

Upper arm including wrist unit:

Fit the lifting eye, VLBG M12 to the attachment hole for lifting eye on the upper arm tube.



Shown in the figure



Fit one of the pieces included in lifting accessory, upper arm to the front attachment for lifting accessory on the upper arm.





Upper arm without wrist unit:

Fit the lifting accessory, upper arm to both attachments for lifting accessory .

Note

The different attachment points, depends on whether the wrist unit is mounted or not!





4 Repair


Continued

8

9

Action Note

Fasten the lifting tool (chain) onto the lifting eye, the lifting accessory and an overhead crane.



Drain the oil from gearbox axis 3.

Detailed in section


.

10 Disconnect connector R2.M5/6 at the cable harness division as well as all remaining connections between upper and lower arm.

Shown in the figure


11 Remove the cover on top of the motors, axis 3 and

4 and disconnect all connectors inside the motors.

12 Remove all brackets securing the cabling to the upper arm by removing their attachment screws respectively.

13

CAUTION

The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting accessory to avoid injury to personnel!

14 Raise the lifting equipment to take the weight of the upper arm.

15 In order to release the brake of the axis 3 motor, connect the 24 VDC power supply.

Connect to connector R2.MP3

• +: pin 2

• -: pin 5

Note

When releasing the brake, the position of the upper arm is adjusted to the position given by the lifting equipment.

16 Remove the axis-3 motor.

17 Carefully remove the attachment screws and washers, upper arm.

See

Replacement of motor, axis 3 on page 331

.

Shown in the figure


18 Lift the upper arm and place it on a secure surface.

Make sure the lift is done completely level! In case of necessary adjustments, use the shortening loops on the lifting tool (chain), but make sure to place the chain the right way through the loops!

19 Remove the sealing, axis 2/3 from the lower arm.

Shown in the figure






269

4 Repair


Continued

Refitting, upper arm

The procedure below details how to refit the upper arm.

1

Action Note

Fit the new sealing, axis 2/3 onto the axis-3 gearbox and keep it in place by also fitting the two guide pins, sealing axis 2/3 in two of the attachment screw holes on the gearbox, see figure to the right.

Always use a new sealing when reassembling!



2

3 xx0200000166

A Holes for the guide pins (sealing axis 2/3).

B Holes for the upper arm attachment screws (33 pcs).

C Holes for the gearbox attachment screws (not affected in this instruction).


Fit the lifting eye, VLBG M12 to the attachment hole, lifting eye on the wrist unit.



Shown in the figure



Fit one of the pieces included in the lifting accessory, upper arm to the front attachment for the lifting accessory on the upper arm.

Upper arm without wrist unit:

Fit the lifting accessory, upper arm to the both attachments for the lifting accessory on the upper arm.



Attachment points are shown in the figure

Location of upper arm on page 264

.

Note

The different attachment points, depends on whether the wrist unit is mounted or not!

4 Fasten the lifting tool (chain) onto the lifting eye, the lifting accessory and an overhead crane.



5

CAUTION

The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting accessory to avoid injury to personnel!





4 Repair


Continued

6

Action

Lift the upper arm and move to its mounting position.

Note

CAUTION

Make sure the lift is done completely level!

7

8

Fit in the gearbox attachment holes with the attachment holes on the lower arm with the guide pins.


ment on page 267 .

Required equip-

Fit the three washers to be placed beneath the attachment screws.

Shown in the figure


9

10

Insert 31 of the 33 attachment screws, upper arm into the attachment holes in the lower arm.

Shown in the figure


Do not remove the guide pins until the attachment screws are tightened as detailed below.

Removing the plastic mechanical stops may be required before fitting the upper arm.

If guide pins are removed before the screws are tightened, the sealing can be involuntarily moved into wrong position.

Secure the lower arm to gearbox axis 3, with the attachment screws.

33 pcs: M12 x 50; 12.9 quality UN-

BRAKO, tightening torque: 120 Nm.



before fitting.

11 Remove the guide pins and fit the two remaining attachment screws. Tighten them as detailed above!

12 Refit the axis-3 motor.

See

Replacement of motor, axis 3 on page 331

.

13 Remove the lifting accessories.

14 Refit any cabling removed during the removal process.

15 Reconnect all connectors inside motors, axis 3 and 4. Refit the motor covers.

16 Reconnect connector R2.M5/6 gently at the cable harness division point, with 2 screws, M6.


17 Perform a leakdown test.

Detailed in section

Performing a leakdown test on page 212 .

18 Refill the gearbox with oil.

Detailed in section

Changing oil, axis-

3 gearbox on page 180

.





271

4 Repair


Continued

19

Action


20

DANGER



.

Note




Calibrating with Axis Calibration method on page 401

.



.

272




4 Repair

4.4.4 Replacement of complete lower arm

4.4.4 Replacement of complete lower arm

Location of lower arm

The lower arm is located as shown in the figure below.



xx0300000474

A

B

C

D

Lower arm

Pivot point, axis 2

Front shaft, balancing device, including securing screw

Attachment for lifting equipment, balancing device

Internal components, lower arm

The internal components of the lower arm are located as shown in the figure below:

• The figure (1) shows a cut between the lower arm and the gearbox axis 3.

The location of the sealing axis 2/3 is identical between the lower arm and the axis 2.

• The figure (2) shows a cut through the lower arm pivot point in axis 2 (item

B in the figure above!).





273

4 Repair


Continued

(1)

P

P-P

R

N

R

P

J

L K

A

B, C xx0300000475

L

N

J

K

A

B

C

Gearbox

Cover axis 2

O-ring

Shaft, balancing device

Grease

Securing screw and washer, balancing device shaft

Attachment screws and washers

R-R

(2)


274




Internal components for robots with protection Standard

4 Repair


Continued

I

H

F

E

D

G

R

M

R

R-R xx1100000955

F

G

D

E

H

I

M

Bearing

Thrust washer

Bushing

Retaining ring, shaft

Shaft, lower arm

Protection washer

Protection plug





275

4 Repair


Continued

Internal components for robots with protection Foundry Plus xx1100000954

H

J

F

G

K

L

M

C

D

E

A

B

Bearing

Thrust washer

Bushing

Shaft, lower arm

Set screw with cup point, M4x6 (2 pcs)

Hexagon bolt M8x190

Conical spring washer

Shaft tap

Short shaft sealing cover

O-ring

Sealing cover

Radial sealing with dust lip


Equipment, etc.

Bearing

Sealing, axis 2

Art. no.

Note

For spare part number see:

•


Always use a new bearing when reassembling!


•







4 Repair


Continued

Equipment, etc.

VK-Cover VK 120x12

Lifting eye M12

Art. no.

Note


•


Mount on new lower arm or replace if damaged.

3HAC14457-3 Used to lift the balancing device, if it is equipped with a threaded hole.

Shackle, balancing device 3HAC 020997-1

Puller tool, balancing device shaft

3HAC12475-1

Lifting accessory, lower arm 3HAC14691-1

Rotation tool 3HAC17105-1

Tool that may be rented from ABB Robotics.

Includes:

• two guidings, 3HAC 14445-1, must be used for guiding the sealing, axis 2/3.

Used to rotate the motor pinion and gear if necessary, when brakes are released.

Hydraulic pump, 80 MPa


(Glycerin)

Puller device, axis 2 shaft

3HAC13086-1

3HAC021563-012

3HAC021563-001 The use of the tool is detailed in section


.

Press device, axis 2 shaft

Press tool, axis 2 bearing

Retaining ring plier

Grease

Isopropanol

Standard toolkit


3HAC021600-001

3HAC13527-1

-

3HAB3537-1

-

11771012-208

For lubrication of the shaft hole.

For cleaning of the shaft.








277

4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, lower arm

The procedure below details how to remove the complete lower arm.

1

Action


Note

2

DANGER

Turn off all:





3

4

Remove the upper arm .

Disconnect and remove the cables from inside the lower arm.

Release any cable attachments.

Detailed in section

Removal, upper arm on page 268 .

Detailed in section


.


278




4 Repair


Continued

5

6

7

8

Action Note

Apply the lifting eye, M12 to the balancing device and raise to unload the weight of the device.



.

Attachment is shown in the figure

Location of lower arm on page 273 .

Unload the balancing device in order to make the piston rod and front ear adjustable when pulling the front shaft out.

Method 1 detailed in section

Unloading the balancing device using hydraulic press tool on page 313

Remove the securing screw from the balancing device front shaft.

Shown in the figure

Location of lower arm on page 273 .

Apply the puller tool, balancing device shaft to the shaft of the balancing device, through the hole in the frame.

The shaft has a M20 thread diameter, as shown in the figure to the right.

Pull the shaft out using the puller tool and the hydraulic pump.



.

xx0300000060

Note

The dimension of the shaft puller tool is M20. Do not mix up with the shaft press tool used when mounting the shaft.

9 Lower the balancing device until it rests safely against the bottom of the frame.

10 Move the lower arm backwards to the lowest position possible.

11 Apply the lifting accessory to the lower arm.

12 Drain the oil from gearbox 2.

13

CAUTION

The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly!

14 Raise the tool to unload the lower arm.

xx0400001028



.

Detailed in section


.




279


4 Repair


Continued

Action

15 Remove the lower arm shaft and all additional components, as detailed in section


.

Note

16 Remove the attachment screws and washers that attach the lower arm to the gearbox axis 2.

Shown in the figure

Internal components, lower arm on page 273

.

17 Lift the lower arm and place it on a secure surface.

Refitting, lower arm

The procedure below details how to refit the lower arm.

Action Note

1

DANGER

Turn off all:





2

3

Fit a new VK-cover on a new lower arm or replace the existing if damaged.

Part no. is specified in


.

Fit two guidings in the attachment holes of the lower arm.



4

5 xx0300000548

A: Attachment holes for the two guidings

Fit the new sealing, axis 2/3 on the guidings.




Apply the lifting tool to the lower arm.



6

CAUTION

The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly!





4 Repair


Continued

7

8

Action Note

Lift the lower arm and move it to its mounting position.

In case the hole pattern of the lower arm and the gearbox axis 2 does not match, use power supply to release the motor axis 2 brakes and rotate the pinion and gear with the rotational tool.

Connect power supply to connector

R2.MP2

• +: pin 2

• -: pin 5 xx0200000165

The rotation tool (A) is used beneath the motor cover, directly on the motor shaft as shown in figure above.



9 Disconnect the power supply, if used.

10 Secure the lower arm with 16 of the 18 attachment screws and washers in gearbox, axis 2.

18 pcs: M16 x 50, tightening torque:

300 Nm.



before fitting.

Shown in the figure

Internal components, lower arm on page 273

.

11 Remove the guidings and secure the two remaining screws as detailed above!

12 Refit the lower arm shaft and all additional components, as detailed in section


.

13 Remove the lifting tool from the lower arm.

14 Refit and restore the balancing device.

15

16

Refit the upper arm.

Perform a leak-down test.

See section

Replacing the balancing device on page 306

.

See section

Refitting, upper arm on page 270

.

See section


.

17 Refill the gearbox with oil.

See section


.

18 Refit and reconnect all cables inside the lower arm.

Resecure any cable attachments.

Detailed in section


.





281

4 Repair


Continued

19

Action

Recalibrate the robot!

20

DANGER



Note





.



.

282




4 Repair

4.4.5 Replacement of lower arm shaft

4.4.5 Replacement of lower arm shaft

Prerequisites

This section details how to remove and refit the lower arm shaft as a step in the procedure of removing/refitting the complete lower arm. To perform the procedure described in this section, it is required that the preceding instructions in section


are followed! These include:

• removing the upper arm

• removing the cabling in the lower arm

• unloading the balancing device and removing the front eye shaft

• draining the oil in gearbox axis 2

• unloading the lower arm with specific lifting equipment.

Components, lower arm shaft for robots with protection Standard

The figure shows components fitted to the lower arm shaft when the robot has protection Standard.

The figure shows IRB 6600, but is also valid for IRB 6650S!

xx0300000487

D

E

F

A

B

C

Protection plug

Lower arm shaft (axis 2 shaft)

Thrust washer

Bearing

Protection washer

Retaining ring





283

4 Repair


Continued

Components, lower arm shaft for robots with protection Foundry Plus

The figure shows components fitted to the lower arm shaft when the robot has protection Foundry Plus.

xx1100000954

F

G

H

C

D

A

B

E

L

M

J

K

Bearing

Thrust washer

Bushing

Shaft for the lower arm

Set screw with cup point, M4x6 (2 pcs)

Hexagon bolt M8x190

Conical spring washer 8.4x16x1.6

Shaft tap

Shaft for the sealing cover

O-ring

Sealing cover

Radial sealing with dust lip


Equipment

Bearing





•


.


3HAC021563-001

3HAC021600-001





4 Repair


Continued

Equipment Article number

Hydraulic pump, 80 MPa 3HAC13086-1

Hydraulic pump, 150 MPa (Glycerin)

3HAC021563-012


Retaining ring plier

Isopropanol

Grease

Glycerin

Rust preventive

3HAC13527-1

-

11771012-208

3HAB3537-1

-

3HAC026621-001

Locking liquid (only for robots with protection Foundry Plus and

Foundry Prime)

3HAB7116-1

Note

For cleaning the shaft.

For lubrication of the bearing.

For lubrication of the shaft.

Equivalent:

• Mercasol 3106

Loctite 243

Puller device for removal of axis 2 shaft

The illustration below shows the puller tool used to remove the lower arm shaft

(axis 2 shaft).

xx0400001029

A

B

Nipple for the hydraulic pump

Nipple for the glycerin pump





285

4 Repair


Continued

Press device for refitting of axis 2 shaft

The illustration below shows the press tool used to refit the lower arm shaft (axis

2 shaft).

xx0400001030

A

B

C

Nipple for the hydraulic pump

Nipple for the glycerin pump

Indicator

Removal, lower arm shaft from robot with protection Standard

Use this procedure to remove the lower arm shaft if the robot has protection

Standard.

If encountering any problems when removing the shaft, contact ABB Robotics!


1

WARNING

This procedure is a step in the complete procedure of removing the lower arm! Make sure all the preceding steps specified in


are made before removing the lower arm shaft!

2 Remove the protection plug.

Shown in the figure

Components, lower arm shaft for robots with protection

Standard on page 283

!





4 Repair


Continued

3

4


Remove the protection washer and the retaining ring.

Shown in the figure

Components, lower arm shaft for robots with protection

Standard on page 283

!

Use a plier for the retaining ring.

Fit the puller device to the shaft as shown in the figure to the right.



xx0300000010

5

6

7

Fit both the hydraulic pump and the glycerin pump to the puller device.



The attachments on the tool are shown in figure

Puller device for removal of axis

2 shaft on page 285 .

Increase the pressure of the glycerin pump and, at the same time, pull out the shaft with the puller tool by increasing the pressure of the hydraulic pump.

Note!

Do not exceed the limit of maximum pressure classified for the pumps!

Remove the bearing and thrust washer from the shaft hole in the lower arm, recommendable after removing the complete lower arm as detailed in section

Replacement of complete lower arm on page 273 .





287

4 Repair


Continued

Removal, lower arm shaft on robot with protection Foundry Plus

Use this procedure to remove the lower arm shaft if the robot has protection Foundry

Plus.

If encountering any problems when removing the shaft, contact ABB Robotics!

Action Note

1

WARNING

This procedure is a step in the complete procedure of removing the lower arm! Make sure all the preceding steps specified in


are made before removing the lower arm shaft!

2

3

4

5

6

7

Remove the two set screws .

Remove the shaft sealing cover .

Remove the sealing cover .

Remove the radial sealing , if the lower arm is to be replaced with a new one.

If the same lower arm is refitted, the radial sealing can be left in the lower arm.

Shown in the figure

Components, lower arm shaft for robots with protection Foundry Plus on page 284

.

Remove the hexagon bolt with the washer and shaft tap .

Fit the puller device to the shaft as shown in the figure to the right.



!

xx0300000010


288




4 Repair


Continued

8

Action Note

Fit both the hydraulic pump and the glycerin pump to the puller device.



.

The attachments on the tool are shown in figure

Puller device for removal of axis 2 shaft on page 285

.

9 Increase the pressure of the glycerin pump and, at the same time, pull out the shaft with the puller tool by increasing the pressure of the hydraulic pump.

Note!


10 Remove the bearing and thrust washer from the shaft hole in the lower arm, recommendable after removing the complete lower arm as detailed in section

Replacement of complete lower arm on page 273 .

Refitting, lower arm shaft on robot with protection Standard

Use this procedure to refit the lower arm shaft if the robot has protection Standard.

1

2

3

4

5

6

7

8

9

Action

Clean the shaft with isopropanol and lubricate it with glycerin .

Push the shaft in by hand.

Refit the thrust washer to the shaft.




Apply the press device, axis 2 shaft against the shaft.


Components, lower arm shaft for robots with protection Standard on page 283 !



Tighten the M16 nut.


Fit both the hydraulic pump and the glycerin pump to the press device.



The attachments on the tool are shown in the figure

Press device for refitting of axis 2 shaft on page 286 .

Set the indicator on the press device to zero.

Shown in the figure


Press in the shaft with the hydraulic cylinder by setting the pressure of the hydraulic pump to approximately 35-55 MPa and the pressure of the glycerin pump to 55 MPa.

Increase the pressure of the both pumps alternately until the correct value is reached with the indicator on the press tool.

Correct value: 2.45 mm ± 0.15 mm.

Note






289

4 Repair


Continued

Action

10 When a correct value is reached, release the pressure from the glycerin pump first, then from the hydraulic pump (approximately 1/2 minute after), in order to avoid movement of the shaft.

11 Remove the press device, axis 2 shaft.


12 Apply grease to the location of the shaft where the bearing is to be mounted.



13 Press in the new bearing with the press tool, axis

2 bearing .




14

15

Refit the protection washer and the retaining ring .

Refit the protection plug .

Shown in the figure

Components, lower arm shaft for robots with protection Standard on page 283

.

16 Proceed with the refitting procedure of the lower arm, detailed in section


.

Refitting, lower arm shaft on robot with protection Foundry Plus

Use this procedure to refit the lower arm shaft if the robot has protection Foundry

Plus.

1

5

6

2

3

4

7

8

9

Action

Clean the shaft with isopropanol and lubricate it with glycerin .

Push the shaft in by hand.

Refit the thrust washer to the shaft.





Components, lower arm shaft for robots with protection Foundry Plus on page 284 !

Apply the shaft.

press device, axis 2 shaft

Tighten the M16 nut.

against the Art. no. is specified in



Fit both the hydraulic pump and the glycerin pump to the press device.



The attachments on the tool are shown in the figure


Set the indicator on the press device to zero.

Shown in the figure


Press in the shaft with the hydraulic cylinder by setting the pressure of the hydraulic pump to approximately 35-55 MPa and the pressure of the glycerin pump to 55 MPa.

Increase the pressure of the both pumps alternately until the correct value is reached with the indicator on the press tool.

Correct value: 2.45 mm ± 0.15 mm.

Note!






4 Repair


Continued

Action

10 When a correct value is reached, release the pressure from the glycerin pump first, then from the hydraulic pump (approximately 1/2 minute after), in order to avoid movement of the shaft.

11 Remove the press device, axis 2 shaft.


12 Apply grease to the location of the shaft where the bearing is to be mounted.



13 Press in the new bearing with the press tool, axis

2 bearing .




14

15

Fit a radial sealing to the lower arm, if there is none left during removal of the arm.

Refit the hexagon bolt with a spring washer and a shaft tap through the hole in the lower arm shaft.

Shown in the figure

Components, lower arm shaft for robots with protection Foundry Plus on page 284 .

16 Fit the shaft for the sealing cover onto the hexagon bolt and tighten the bolt with torque: 24 Nm.

17 Check the o-ring in the sealing cover. Replace if damaged.

18 Refit the sealing cover onto the shaft. Press it tightly against the radial sealing while tightening the set screws. Use locking liquid.

19 Proceed with the refitting procedure of the lower arm, detailed in section


.




291

4 Repair

4.4.6 Securing the lower arm

4.4.6 Securing the lower arm

General

This section details how to secure the lower arm with a specific fixture prior to performing certain service activities to the robot.

Attachment points, robot

The special equipment used to secure the lower arm is fitted to the attachment points shown in the figure below.

xx0300000608

A

B

C

Attachment hole, securing screw

Holes for M12 bolts

Holes for M16 bolts


Equipment, etc

Fixture lower arm

Art. no.

3HAC020729-001

Note

Includes the locking screw for securing the lower arm.





4 Repair


Continued

Equipment, etc

Standard toolkit

Art. no.

3HAC 15571-1

Note



in part 2 of the

Product manual.

Fixture, lower arm

The attachment bolts, locking screw, adjusters and ring nuts are attached to the fixture tool as shown in the figure below. Move them to the attachment points shown in the instruction.

xx0300000609

C

D

A

B

E

Locking screw

Adjusters, 2 pcs

M16 bolts, 4 pcs

Ring nuts, 2 pcs

M12 bolts and washers, 2 pcs





293

4 Repair


Continued

Securing the lower arm

The procedure below details how to secure the lower arm by fitting the fixture to the robot.


1

DANGER

Turn off all:





2

3

Remove any load or equipment fitted to the upper arm or turning disk.

Move the robot to the calibration position. The upper arm can be directed in three different ways, shown in the figure to the right.

The lowered position, as in figure

A, is recommended as it gives the least load on the tool.

xx0200000260

4 If the robot is fitted with moveable mechanical stops on axis 2 (not stock equipment), these must be removed at this point.

The attachment holes of the mechanical stops are used to attach the fixture.


294




4 Repair


Continued

5

6

7

Action

Remove the locking screw from the fixture, where it is attached.


Shown in the figure

Fixture, lower arm on page 293 .

Art. no. of the fixture is specified in


.

Secure the lower arm to the frame by inserting the locking screw into a specific attachment hole through the frame, into the lower arm.

Shown in the figure

Attachment points, robot on page 292

.

Fit the fixture, lower arm to the frame and the lower arm, according to following instruction:

1 Fit the both adjusters in the correct holes and make sure that they are screwed back (C).

2 Align the fixture with the frame and lower arm.

3 Make sure the fixture is pressed tightly against the lower arm before securing with screws!


page 292

.

Required equipment on

Attachment holes on the frame and on the lower arm are shown in the figure

Attachment points, robot on page 292 !

The adjusters, bolts and ring nuts are shown in the figure

Fixture, lower arm on page 293 .

4 Fit and tighten the four M16 bolts in the attachment holes on the inside of the frame with tightening torque: 220 Nm (A).

5 Screw in the two adjusters until they rest against the flats on the lower arm.

Tighten by hand.

6 Lock, using the two ring nuts.

7 Fit and tighten the two M12 bolts in the attachment holes on the lower arm with tightening torque: 91 Nm

(C).

8 The lower arm is now secured and it is safe to remove the gearbox of axis 2, according to section

Removal, gearbox axis 2 on page 370 ,

provided that the balancing device is unloaded.

xx0300000610

• A: Holes for M16 bolts. Choose the 2 suitable holes for current robot model.

• B: Holes for M16 bolts.

• C: Holes for M12 bolts (2 pcs), adjusters, ring nuts and washers. Choose the suitable holes for current robot model.




295

4 Repair

4.5.1 Replacing the SMB unit

4.5 Frame and base

4.5.1 Replacing the SMB unit

Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure.

Required equipment xx0300000557

A

B

C

SMB cover

SMB unit

Battery cable

Note

There are different variants of SMB units and batteries. The variant with the

3-pole battery contact has longer lifetime for the battery.

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!

Equipment, etc.

SMB unit

Article number

For spare part number, see:


Note





4 Repair


Continued

Equipment, etc.

Standard toolkit

Circuit diagram -

-




.

See chapter


Removing, SMB unit

Use this procedure to remove the SMB unit.

1

2

Action

Move the robot to the calibration position.

DANGER

Turn off all:




Note

3


The unit is sensitive to ESD. Before handling the unit read the safety information in section


4 Remove the SMB cover by unscrewing its attachment screws.

Shown in the figure

Location of

SMB unit on page 296 .

CAUTION



5

6

7

8

Use caution and remove the connectors X8, X9 and

X10 from the brake release board, if need of more space.

Remove the nuts and washers from the guide pins that secure the board.

Shown in the figure

Location of

SMB unit on page 296 .

Use caution and disconnect the connectors from the

SMB unit when pulling the board out.

Connectors R1.SMB1-3,

R1.SMB4-6 and R2.SMB

Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards.




xx1700000993


297

4 Repair


Continued

Refitting, SMB unit

Use this procedure to refit the SMB unit.

Action

1

DANGER

Turn off all:




Note

2




3

4

5

6

7

Connect the battery cable to the SMB unit.

Make sure the lock on the battery cable connector R2.G snaps into place during refitting.

Shown in the figure

Location of SMB unit on page 296 .

Connect all connectors to the SMB board:

R1.SMB1-3, R1.SMB4-6 and R2.SMB



.

Shown in the figure


Fit the SMB unit onto the guide pins .

Secure the SMB unit to the pins with the nuts and washers.

If disconnected, reconnect the connectors X8,

X9 and X10 to the brake release board.

Be careful not to damage the sockets or pins.

Make sure the connector and its locking arms are snapped down properly.

X9

X8

X10 xx1700000978

8

9

Secure the SMB cover with its attachment screws.

If cabling is used for 7th axis (option), refit the

7th axis connector to the SMB cover and tighten with 6 Nm.

Shown in the figure


Update the revolution counter!

See

Updating revolution counters on page 396

.

10

DANGER






4 Repair

4.5.2 Replacing the brake release board

4.5.2 Replacing the brake release board

Location of brake release board

The brake release unit is located together with the SMB unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below.

xx0300000558

A

B

C

D

Brake release unit

SMB cover

Bracket

Push button guard


Equipment, etc.

Brake release board

Standard toolkit


-


3HAC065020-

001

DSQC1050


tools on page 435

.

Standard






299

4 Repair


Continued

Removing, brake release board

Use this procedure to remove the brake release board.

Action Note

1

DANGER

Turn off all:





2

ELECTROSTATIC DISCHARGE

(ESD)



3

4

Remove the push button guard from the SMB cover.

Shown in the figure

Location of brake release board on page 299

.

The guard must be removed to ensure a correct refitting of the brake release board.

Open the SMB cover by unscrewing the attachment screws.

Let the battery stay connected, to avoid the need of synchronization of the robot!

Shown in the figure


.

CAUTION



5

6

7

Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board.

Remove the complete brake release board

(including brake release board and bracket) from the SMB recess, by removing its two attachment screws.

Disconnect the connectors X8, X9 and X10 from the brake release board.

X9

X8

X10 xx1700000978

Location of the brake release unit is shown in the figure


.





4 Repair


Continued

8

Action

Remove the brake release board from the bracket by removing the four attachment screws.

Note

Refitting, brake release board

Use this procedure to refit the brake release board.

Action Note

1




2 Connect the connectors X8, X9 and X10 to the brake release board.

Be careful not to damage the sockets or pins.

Make sure the connector and its locking arms are snapped down properly.

X9

X8

X10 xx1700000978

3 Fasten the brake release board on the bracket with the attachment screws.

Make sure the board is pushed forwards and positioned as straight as possible on the bracket when fastening with the attachment screws. The push buttons can otherwise get jammed when the SMB cover is refitted.

Maximum tightening torque: 5 Nm.

Shown in the figure


.



.

xx1700001153

4 Refit the complete brake release board (including brake release board and bracket) to the

SMB recess with the two attachment screws.





301

4 Repair


Continued

5

Action

Verify that the robot cabling is positioned correctly, according to previously taken picture/notes.

Note

WARNING

Screened cables must not get in contact with the brake release board after installation.

Eliminate all risks of contact between screened cables and the brake release board.

6 Refit the SMB cover with its attachment screws.

7

WARNING

Before continuing any service work, follow the safety procedure in

The brake release buttons may be jammed after service work on page 218 .

Shown in the figure


.

8

9

Refit the push button guard to the SMB cover.

Shown in the figure


.

Press the push buttons 1 to 6, one at a time, to make sure that the buttons are moving freely and do not stay in a locked position.

10 If the battery has been disconnected the revolution counter must be updated.

Detailed in the Calibration chapter section


.

11

DANGER



302




4 Repair

4.5.3 Replacement of spherical roller bearing, balancing device

4.5.3 Replacement of spherical roller bearing, balancing device

Location of bearing

The bearing is located at the front ear of the balancing device, as shown in the figure below.

xx0500002249

A

B

C

D

E

Spherical roller bearing

Sealing ring

O-ring

Sealing spacer

Front ear of balancing device


Equipment

Spherical roller bearing

Sealing spacer

O-ring

Sealing ring

Grease

Spare part no.

3HAA2167-17

3HAC12988-1

3HAB3772-76

3HAC11581-6

Art. no.

3HAB3537-1



Note

2 pcs required.

2 pcs required.

2 pcs required.

For lubrication of the components.


303


4 Repair


Continued

Equipment

Toolkit

Other tools and procedures may be required.

See references to these procedures in the step-by-step instructions below.

Spare part no.

Art. no.

3HAC15943-1

Note

The tools in the set are shown in the section Tool set.


Tool set

The parts of the tool set for replacing the spherical roller bearing are shown in the figure.

xx0500002259

D

E

F

A

B

C

Threaded bar

Dolly

Press tool for removal of bearing

Press tool for refitting of bearing

Hexagon nut M12 (2pcs)

Plain washer 13x24x2,5 (2pcs)

Removal, spherical roller bearing

Use this procedure to remove the spherical roller bearing from the balancing device front ear.

Action Note

1

DANGER

Turn off all:









4 Repair


Continued

2

3

4

5

6

Action

Remove the balancing device from the robot.

Remove the both sealing spacers with a screwdriver or any equal tool.

Note

Detailed in section

Replacing the balancing device on page 306 .

Shown in the figure

Location of bearing on page 303

.

Insert the threaded bar through the bearing.

Fit the press tool and dolly to the threaded bar.

Secure with the nut and washer at each end.

Press out the bearing from the front ear.

A Threaded bar 3HAC15945-1

B Dolly 3HAC15948-1

C Press tool 3HAC15941-1

Refitting, spherical roller bearing

Use this procedure to refit the spherical roller bearing to the balancing device front ear.

Action Note

1

DANGER

2

3

4

5

6

Turn off all:





Grease the inside walls of the front ear.

Press in the bearing properly inside the ear.

Apply grease to the new sealing rings and o-rings and fit one of each to the new sealing spacers . Also, grease the sealing spacers.

Spare part no:s are specified in


.

Refit the balancing device to the robot.

Detailed in section

Refitting, balancing device on page 310

.

Lubricate the spherical roller bearing in the ear.

Detailed in section

Lubrication of spherical roller bearing, balancing device on page 196

Note

The balancing device must be mounted on the robot when lubrication is performed!

7 Make sure no incorrect leakage occurs. It could indicate damaged o-rings.



8

DANGER



.




4 Repair

4.5.4.1 Replacing the balancing device

4.5.4 Replacement of balancing device

4.5.4.1 Replacing the balancing device

Location of balancing device

The balancing device is located on rear top of the frame as shown in the figure below.

xx0300000533

G

H

E

F

A

B

C

D

Balancing device

Rear cover

Support shaft inside

Attachment screws, rear cover

Balancing device shaft, including securing screw

Bearing attachment

Parallel pin (inside bearing attachment)

Attachment screws, bearing attachments


306




4 Repair


Continued

Attachment points, balancing device

The attachment points for the lifting tools etc. are located as shown in the figure below.

xx0300000481

B

C

D

E

Lifting eye for the lifting equipment

Securing screw attachment hole, secures the bearing attachment to the balancing device (remove the protection plug)

Hole in the frame to access the balancing device shaft with the puller/press tool

Locking screw attachment hole, secures the lower arm to the frame


Equipment

Balancing device



Spare part no.

See


.

Art. no.

Note

Includes balancing device

3HAC020040-001!

Includes o-rings 3HAB3772-

44.


307


4 Repair


Continued

Equipment

O-ring

Locking screw

Securing screw

Bearing grease

Grease

Locking liquid

Grease pump


Lifting eye M12

Shackle, balancing device


Press tool, balancing device


Press tool, balancing device shaft

Hydraulic cylinder

Hydraulic pump, 80

MPa

Hydraulic valve with hose

Standard toolkit


Spare part no.

-

Art. no.

3HAB3772-44

3HAA1001-266

9ADA183-66

3HAB3537-1

3HAA1001-294

Note

3 pcs, to be replaced if damaged!

M16 x 60

For securing the lower arm.

M12 x 35, 2 pcs required

For securing the bearing attachments to the balancing device when lifting.

For lubricating the o-rings and the shaft.

80 ml, Optimol PDO

For lubrication of spherical roller bearing in ear, in case of new balancing device.

Loctite 243

To apply to the securing screw in the shaft.

To lubricate spherical roller bearing.


-

3HAC13120-5

3HAC14457-3

3HAC 020997-1

-

3HAC15556-1

3HAC020902-001

3HAC12475-1

3HAC17129-1

3HAC11731-1

3HAC13086-1

3HAC022643-001

To be used with the press and puller tools.

2 pcs required!

To be used with the hydraulic cylinder.








4 Repair


Continued

Removal, balancing device

The procedure below details how to remove the balancing device.

1

Action

Move the lower arm to a position close to the calibration position.

Note

2

DANGER

3

Turn off all:





Secure the lower arm to the frame by inserting the locking screw into the attachment hole in the frame.

Attachment hole for the locking screw is shown in the figure

Attachment points, balancing device on page 307 .



4

CAUTION

The balancing device weighs 407 kg! All lifting equipment used must be sized accordingly!

5

6

7

8

Apply the lifting eye and the shackle to the attachments on the balancing device and raise to unload the weight.



Attachments are shown in the figure

Attachment points, balancing device on page 307

.

Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out.



Detailed in section


.

Remove the securing screw from the balancing device shaft.

Shown in the figure

Location of balancing device on page 306 !

Apply the puller tool, balancing device shaft to the shaft through the hole in the frame.

The shaft has a M20 thread diameter, as shown in the figure to the right.

Pull the shaft out using the puller tool and the hydraulic pump.



The hole in the frame is shown in the figure

Attachment points, balancing device on page 307 !



Note

Make sure to keep the balancing device unloaded by keeping the tap to the press device closed and using the second hose of the hydraulic valve to the puller tool.

xx0300000060

Note

The dimension of the shaft puller tool is M20. Do not mix up with the shaft press tool used when mounting the shaft.


309


4 Repair


Continued

9

10

11

12

13

Action

Restore the balancing device.

Note

Detailed in section

Restoring the balancing device using a hydraulic press tool on page 317

.

Secure the two bearing attachments to the balancing device by replacing the protection plug on the outside of each attachment, with securing screws.

The protection plugs must be refitted after refitting the balancing device, do not loose them!

Shown in the figure

Attachment points, balancing device on page 307 !

Dimensions for the securing screws are specified in


.

Remove the two bearing attachments from the frame by unscrewing their four attachment screws.

Shown in the figure


Make sure the parallel pins inside are not lost!

Fit two guide pins through the upper holes of the bearing attachments, to the frame.



Lift the balancing device gently backwards to a secure area, allowing the bearing attachments to slide on the guide pins.

Note

Make sure not to burden the guide pins with the weight of the balancing device!

Refitting, balancing device

The procedure below details how to refit the balancing device.

Action Note

1

DANGER

Turn off all:





2

3

4

5

Secure the lower arm to the frame by inserting the locking screw into the attachment hole in the frame.



!

Attachment hole is shown in the figure


.

Secure the bearing attachments to the balancing device with securing screws .

Shown in the figure


!

Dimension of the securing screws is specified in


.

Refit the two parallel pins in the frame.

Shown in the figure


Fit two guide pins to the upper holes in the frame, where the bearing attachments are to be attached.


310




4 Repair


Continued

6

Action Note

Fit the lifting eye and the shackle to the attachment points on the balancing device.



!

Attachments are shown in the figure


.

7

8

9

10

11

12

13

14

15

CAUTION

The balancing device weighs 407 kg! All lifting equipment used must be sized accordingly!

Lift the balancing device and bring it forward, gliding the bearing attachments on to the guide pins.

Note

Make sure not to burden the guide pins with the weight of the balancing device!

Remove the guide pins.

Secure the rear of the balancing device by fastening the two bearing attachments to the frame with their four attachment screws.

Shown in the figure


4 pcs, M16x70, 12.9 quality UN-

BRAKO, tightening torque: 300 Nm.



before fitting.

Remove the screws from outside of the bearing attachments and refit the protection plugs.

Raise the balancing device to a position where the balancing device shaft may be inserted through the piston shaft front eye.

Unload the balancing device with the press tool.

Detailed in section


.



!

For an easier reassembling of the shaft, the piston rod may be pressed out more than necessary and then pressed in when fitting the shaft.

Lubricate the shaft with grease.



!

Apply the shaft press tool to the lubricated shaft .

Fit the shaft to the piston shaft front eye through the hole in the frame, using the shaft press tool and the hydraulic pump .

The hole in the frame is shown in the figure


!



!

Note Note

Make sure to keep the balancing device unloaded by keeping the tap to the press device closed and using the second hose of the hydraulic valve to the puller tool.

Make sure the shaft is pressed all the way to the bottom.




311


4 Repair


Continued

16

17

18

Action

Refit the securing screw into the shaft using locking liquid.

Note

M16 x 180, tightening torque: 120

Nm.



Lubricate the bearing in the ear with grease through the lubricating nipple, with a grease pump.

Fill until excessive grease pierces between the shaft and the sealing spacer.

Art. no. and amount are specified in


Lubrication is further detailed in section

Lubrication of spherical roller bearing, balancing device on page 196

.


Detailed in section


.

19

20

DANGER

The rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before commissioning of the robot!

Remove the locking screw that secures the lower arm to the frame.

21

DANGER



xx0300000484

Attachment hole for the securing screw.

312




4 Repair

4.5.4.2 Unloading the balancing device using hydraulic press tool

4.5.4.2 Unloading the balancing device using hydraulic press tool

Prerequisite

This section details how to unload the balancing device using the hydraulic press tool.

The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, for example removal of the balancing device.

DANGER

There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property.

Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.

The press tool includes two press devices that are used to different models of the balancing device.

xx0200000174

A

B

Press block

Hydraulic cylinder





313

4 Repair


Continued

C

D

E

F

G

Press device

Bolt, press device

Moving pin with marking

Bolt (4 pcs)

Pin, attached to the fix plate


Equipment, etc.


Hydraulic cylinder



Standard toolkit

Art. no.

3HAC020902-001

3HAC11731-1

Note

Includes

• press device 3HAC15767-2

• press device 3HAC18100-1

Choose the correct device, depending on model of balancing device.

To be used with the press tool.

2 pcs required!

-

3HAC022643-001

3HAC13086-1 To be used with the hydraulic cylinder.



.

Using the correct press device

The different designs of the balancing device require different versions of the press device, included in the complete press tool. The table below specifies which press device to use to which balancing device.

The article number of the balancing device may be found on a label at the rear of the balancing device.

Balancing device

Art. no: 3HAC021204-001

Press device

Art. no: 3HAC15767-2 xx0300000598 xx0300000600


314




4 Repair


Continued

Unloading the balancing device

The procedure below details how to use the press tool in order to unload the balancing device. How to remove the press tool, is detailed in section

Restoring the balancing device using a hydraulic press tool on page 317 .

1

2

Action Note

Fit the moving pin to the current press device.

Choose the correct press device, according to the table

Using the correct press device on page 314 .

The moving pin is shown in the figure

Press tool and hydraulic cylinder on page 313 .

Fit the correct press device and moving pin to the press tool. Secure with the bolt, press device.

Shown in the figure

Press tool and hydraulic cylinder on page 313 .

Note

Make sure the bolt is secured properly!

3 Remove the rear cover of the balancing device, by unscrewing the attachment screws .

DANGER

DO NOT! remove any other screws then the rear cover attachment screws.

4

5

6

7 xx0300000606

• E: Rear cover attachment screws,

8 pcs

Remove

• the o-ring from the balancing device end.

• the support shaft, including the damper, from the balancing device.

• the remaining o-ring from the balancing device end.

Fit the press tool to the rear of the balancing device with enclosed bolts.

Tighten them properly!



.

See the figure

Press tool and hydraulic cylinder on page 313

.

Fit the hydraulic cylinder to the press tool.



.

See the figure


.

Connect the hydraulic pump to the hydraulic valve and connect one of the hoses to the hydraulic cylinder on the press tool.





315

4 Repair


Continued

8

Action

Open the tap to the connected hose. Check that the other tap is closed.

Note

Note

Only one tap may be open at a time!

9 Increase the pressure and press until the front eye of the piston rod is aligned with the hole in the frame, through which the shaft may be pulled out or pressed in.

Note

Make sure the piston rod is properly unloaded before removing the shaft from the front eye, otherwise the shaft may be damaged!

10 Close the tap to the hose.

11 Keep the hydraulic cylinder and pump connected in order to keep the balancing device unloaded in correct position!

The hydraulic pump can be used by connecting the second hose of the hydraulic valve to an other tool.

316




4 Repair

4.5.4.3 Restoring the balancing device using a hydraulic press tool

4.5.4.3 Restoring the balancing device using a hydraulic press tool

Overview

This section details how to restore the balancing device and how to remove the press tool from the device.

DANGER

There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property.

Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.

The press tool includes two press devices that are used to different models of the balancing device.

xx0200000174

C

D

E

A

B

Press block

Hydraulic cylinder

Press device

Bolt, press device

Moving pin with marking





317

4 Repair


Continued

F

G

Bolt (4 pcs)

Pin, attached to the fix plate


Equipment, etc.


Hydraulic cylinder


Locking liquid

Art. no.

3HAC022643-001

3HAC11731-1

-

3HAC13086-1

Note

To be used with press tool.

To be used with hydraulic cylinder.

Loctite 577

Used to secure the attachment screws of the rear cover at the end of the balancing device.



Standard toolkit

Sikaflex 521FC

3HAC15571-1

Restoring the balancing device

The procedure below details how to restore the balancing device, that is removing the press tool.

1

2

3

4

5

6

7

Action

Open the tap on the hydraulic valve to unload the hydraulic cylinder and make sure the moving pin indicates that the tool has returned to its starting position.

Note

Remove the hydraulic cylinder.

Remove the press tool by unscrewing the bolts.

Shown in the figure


!

Lubricate and refit the o-ring at the end of the balancing device.

Make sure the o-ring is seated properly! Replace if damaged.

Make sure the damper is properly fitted to the support shaft and refit them both to the balancing device.

Lubricate and refit the o-ring on the support shaft.

Make sure the o-ring is seated properly! Replace if damaged.

Refit the rear cover to the balancing device with its attachment screws, using locking liquid. Apply sikaflex 521FX on the cover.


318


xx0300000606

• E: 8 pcs: M10x45, tightening torque: 50 Nm.



.



4 Repair


Continued

Action

8

DANGER

The rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before commissioning of the robot!

Note




319

4 Repair

4.6.1 Replacement of motor, axis 1

4.6 Motors

4.6.1 Replacement of motor, axis 1

Note

This procedure requires calibration of the robot.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.

Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant.

Location of motor

The motor axis 1 is located on the left hand side of the robot as shown in the figure below.

xx0300000499

A

B

Motor, axis 1

Motor attachment screws and washers


Equipment, etc.

Spare part no.

Motor including pinion See


.

Art. no.

O-ring


320

21522012-430

Note

Includes

• motor

• pinion

• o-ring 21522012-

430.

Must be replaced when reassemling the motor.




4 Repair


Continued

Equipment, etc.

Mobilux EP 2

Grease

Removal tool, motor

M12x

Lifting tool, motor ax

1, 4, 5

Power supply

-

Spare part no.

Standard toolkit

Calibration Pendulum toolkit

Calibration tool box,

Axis Calibration

-

Art. no.

3HAB3537-1

3HAC14631-1

Note

Used to lubricate the motor clutch.

Used to lubricate the oring.

Always use the removal tools in pairs!

3HAC14459-1

-

-

24 VDC, max. 1,5 A




.

3HAC15716-1

3HAC055412-001

Complete kit that also includes operating manual.

Required if Calibration

Pendulum is the valid calibration method for the robot.

Delivered as a set of calibration tools.

Required if Axis Calibration is the valid calibration method for the robot.



See references to these procedures in the step-by-step instructions below.



.




1

Action




Note





321

4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, motor axis 1

The procedure below details how to remove motor, axis 1.

1

Action


Note

2

DANGER

Turn off all:





3

4

Remove the cover for connector access on top of the motor by unscrewing its four attachment screws.


Note

Make sure the gasket is not damaged!

5

6

7 xx0200000199

• A: Cable gland cover

Disconnect all connectors beneath the motor cover.

Apply lifting tool, motor axis 1, 4, 5 to the motor.



.

In order to release the brakes, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5





4 Repair


Continued

8

Action

Remove the motor by unscrewing its four attachment screws and plain washers.

Note

Shown in the figure

Location of motor on page 320 .

9

CAUTION

The motor weighs 25 kg! All lifting equipment used must be sized accordingly!

10

11

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

Remove the motor by gently lifting it straight up.

Refitting, motor axis 1

The procedure below details how to refit motor, axis 1.

Action Note

1

DANGER

Turn off all:





2 Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the oring with grease.

Art no. is specified in


.

3

CAUTION


7

8

4

5

6

9

10

11

Apply the lifting tool, motor axis 1, 4, 5 to the motor.



.

In order to release the brake, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5

Fit the motor, making sure the motor pinion is properly mated to gearbox of axis 1.

Make sure the motor is turned the correct way, that is connection of motorcable forwards. .

Make sure the motor pinion does not get damaged!

Fit the clutch on the pinion on the motor.

Secure the motor with its four attachment screws and plain washers.

Disconnect the brake release voltage.

M10 x 40, tightening torque: 50

Nm.

Reconnect all connectors beneath the motor cover.


Make sure the cover is tightly sealed!




323


4 Repair


Continued

12

13

Action

Refit the motor cover with its four attachment screws.


14

DANGER



Note


Pendulum Calibration is described in Operating manual - Calibration

Pendulum , enclosed with the calibration tools.





.

324




4 Repair

4.6.2 Replacement of motor axis 2

4.6.2 Replacement of motor axis 2


The motor, axis 2, is located on the left-hand side of the robot as shown in the figure below.

xx0300000500

C

D

A

B

Motor axis 2

Hole for lock screw

Cable gland cover (located on the lower side of the motor)

Motor attachment holes (4 pcs)


Equipment, etc.

Motor including pinion

Spare part no.

See


Art. no.

O-ring

Grease

Locking screw

Removal tool, motor

M12x


21522012-430

3HAB3537-1

3HAA1001-266

3HAC14631-1

3HAC15521-2

Note

Includes

• motor

• pinion

• o-ring 2152 2012-430

Must be replaced when reassembling motor!

For lubricating the o-ring.

M16 x 60

For securing the lower arm.


For guiding the motor.

Guides are to be used in pairs!




325


4 Repair


Continued

Equipment, etc.

Lifting tool, motor ax

2, 3, 4

Extension bar, 300 mm for bits 1/2"

Power supply

Spare part no.

Rotation tool

Standard toolkit



Axis Calibration

Art. no.

3HAC15534-1

3HAC12342-1

Note

-

-

3HAC17105-1

3HAC15716-1

3HAC055412-001

24 VDC, 1.5 A


Used to rotate the motor pinion when mating it to the gear when brakes are released with 24VDC power supply.




Required if Calibration Pendulum is the valid calibration method for the robot.







.




1

Action




Note


326




4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, motor

The procedure below details how to remove the motor, axis 2.

1

2

Action Note


Move the robot to a position close enough to its calibration position, to allow the lock screw to be inserted into the hole for lock screw .

Shown in the figure


3

DANGER

Turn off all:





4

5

6

7

8

Lock the lower arm by inserting the lock screw into the hole.

Art. no. and dimension is specified in


Drain the oil from gearbox, axis 2.



Remove the cover on top of the motor by unscrewing its four attachment screws.


Shown in the figure







327


4 Repair


Continued

9

Action

DANGER

Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2!

When releasing the holding brakes of the motor, the lower arm will be movable and may fall down!

Note

Use the lock screw to lock the lower arm, as detailed above!

10 In order to release the brake, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5

11 Remove the motor by unscrewing its four attachment screws and plain washers.

12 Fit the two guide pins in two of the motor attachment holes.



Shown in the figure


13 If required, press the motor out of position by fitting the removal tool, motor to the remaining motor attachment holes.



Shown in the figure

Location of motor on page 325


.

14 Remove the removal tools and fit the lifting tool, motor axis 2, 3, 4 to the motor.



15

CAUTION


16 Lift the motor to get the pinion away from the gear.


17 Remove the motor by gently lifting it straight out and place it on a secure surface. Disconnect the brake release voltage.

Refitting, motor

The procedure below details how to refit the motor axis 2.

Action Note

1

DANGER

Turn off all:









4 Repair


Continued

2

3

Action Note

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.



.

Foundry Plus :

If the motor is a new spare part, the evacuation hole protection filter must be replaced with a transparent plug/sight glass (enclosed with the spare part delivery). Remove the protection filter and install the transparent plug/sight glass.

Tightening torque, transparent plug: 25

Nm ±10%.

Tightening torque, protection filter: 10

Nm ±10%.

xx1800000101

Protection filter

(Standard).

xx1800000102

Transparent plug

(Foundry Plus).

xx1600000576

4

5

6

In order to release the brake, remove the cover on top of the motor and connect the 24

VDC power supply.


• +: pin 2

• -: pin 5

Fit the lifting tool, motor axis 2, 3, 4 to the motor.



.

Fit the two guide pins in the two lower motor attachment holes.



.

Shown in the figure


.

7

8

9

CAUTION


Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

Make sure that the motor is turned the right direction, that is the cables facing downwards.

Remove the lifting tool and allow the motor to rest on the guide pins.





329

4 Repair


Continued

10

Action Note

Use the rotation tool in order to rotate the motor pinion when mating it to the gear (see the figure to the right). Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox axis 2 and that it does not get damaged.



.

330

11

12

13

14

15

16

17

18

19

20 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in the figure above.

• A: Rotation tool


Secure the motor with four attachment screws and plain washers.

M10 x 40, tightening torque: 50 Nm.



before fitting.



Connect in accordance with markings on connectors.


Shown in the figure


.

Refit the cover on top of the motor with its four attachment screws.


Remove the lock screw from the hole for lock screw.

Shown in the figure


.

Perform a leak down test.

Detailed in


.

Refill the gearbox with oil.

Recalibrate the robot.









21

DANGER



.




4 Repair




The motor axis 3 is located on the left hand side of the robot as shown in the figure below.

xx0200000186

A

B

C

Motor axis 3

Cable gland cover, motor axis 3



Equipment, etc.


Spare part no.

See


.

Art. no.

O-ring


21522012-430

Grease

Removal tool, motor M12x

3HAC12708-1

3HAB3537-1

3HAC14631-1

Note

Includes

• motor

• pinion

• o-ring 21522012-430


May be used to fix axis 3.

Use attachment screws 3HAB

3409-86 (M16 x 60).






331


4 Repair


Continued

Equipment, etc.

Lifting tool, motor ax 2, 3, 4

Bolts M16x60

(for mechanical stop axis 3)

Washers (for mechanical stop axis 3)

Guide pins M10 x

100

Guide pins M10 x

150

Rotation tool

Spare part no.

Power supply

Standard toolkit


Calibration tool box, Axis Calibration


Circuit diagram

Art. no.

3HAC15534-1

3HAB3409-86

3HAA1001-186

3HAC15521-1

Note


3HAC15521-2 For guiding the motor.

-

3HAC17105-1 Used to rotate the motor pinion when mating it to the gear when brakes are released with

24 VDC power supply.

24 VDC, max. 1.5 A


-

3HAC15716-1





3HAC055412-001 Delivered as a set of calibration tools.



See chapter

on page 441

.

Circuit diagram


332




4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, motor


1

2

Action


Note

Unload the upper arm of the robot by either:

• Use a fork lift to rest the upper arm onto.

• Use lifting slings and an overhead crane to rest the upper arm.

• Use a mechanical stop to rest the upper arm. Fit the mechanical stop in the attachment hole (A) with tightening torque: 115 Nm.


3HAC020993-001 Revision: Z xx0300000051

Fit the mechanical stop to the third and final attachment hole (A), below the fixed stop (B) in the upper arm. See the figure above!


333


4 Repair


Continued

Action Note

3

DANGER

Turn off all:





4

5

6

7

8

Drain the oil from gearbox axis 3.

Detailed in section


.

Remove any equipment hindering access to motor axis 3.


Remove the cable gland cover at the cable exit by unscrewing its two securing screws.

Shown in the figure




9 Unscrew the motors four attachment screws and plain washers .

Shown in the figure


10 Fit the two guide pins in two of the motor attachment screw holes.



11 Press the motor out of position by fitting removal tool, motor to the remaining motor attachment screw holes.




12

13

Apply the lifting tool, motor axis 2

,3, 4 to the motor.

CAUTION




14 Lift the motor to get the pinion away from the gear.

15 Remove the motor by gently lifting it straight out and disconnect the brake release voltage.

Make sure the motor pinion is not damaged!


334




4 Repair


Continued



Action Note

1

DANGER

Turn off all:





2

3

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate it with grease .



.

Foundry Plus :


Tightening torque, transparent plug:

25 Nm ±10%.

Tightening torque, protection filter:

10 Nm ±10%.

xx1800000101

Protection filter

(Standard).

xx1600000576 xx1800000102

Transparent plug

(Foundry Plus).

4

5

Fit the lifting tool, motor axis 2, 3, 4 to the motor.



.

Fit the two guide pins in the two lower motor attachment holes.



.

Shown in the figure


6

CAUTION


7

8

9

Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

Remove the lifting tool and allow the motor to stay on the guide pins.



• +: pin 2

• -: pin 5




335


4 Repair


Continued

10

Action Note

Use the rotation tool in order to rotate the motor pinion when mating it to the gear!

Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 3.



.


Make sure the motor is turned the right direction, that is the cables facing forwards.

11

12

13

14

15 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

• A: Rotation tool.




50 Nm.



Connect in accordance with markings on connectors.



Shown in the figure


.

16

17

18

19

20


Remove the equipment used to unload the upper arm.





.





.

Pendulum Calibration is described in Operating manual - Calibration

Pendulum , enclosed with the calibration tools.



.



.


336




4 Repair


Continued

Action

21

DANGER



Note




337

4 Repair




The motor axis 4 is located on the left-hand side of the upper arm as shown in the figure below.

xx0200000202

A

B

C

Motor, axis 4

Cable gland cover, motor axis 4



Equipment, etc.


O-ring



Grease

Loctite 574, Flange sealant

Removal tool. motor M10x

Guide pins M8 x 100

Art. no.

Note

See spare part number in


.

Includes:

• motor

• pinion

• o-ring 21522012-430

21522012-430 Must be replaced when reassembling motor!

3HAC14459-1

3HAC15534-1

3HAB3537-1

12340011-116

3HAC14972-1

3HAC15520-1

Used to lubricate the o-ring.

Option Foundry Plus







4 Repair


Continued

Equipment, etc.

Guide pins M8 x 150

Rotation tool

Power supply

Standard toolkit


-

Art. no.

3HAC15520-2

3HAC17105-1

-

3HAC15716-1


3HAC055412-001

Note


Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply.

24 VDC, max. 1,5 A




.









.




1

Action Note










Axis Calibration in


.






339


4 Repair


Continued

Action




Note

Removal, motor axis 4


1

2

Action


Note

Move the robot to a position where the upper arm is pointed straight up.

This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

Any other position of the upper arm requires a draining of oil from the gearbox for axis 4.

Draining of oil is described in section

Draining, oil on page 183

.

3

DANGER

Turn off all:





4

5

6

7

8

Remove the cable gland cover at the cable exit of the motor by unscrewing its two attachment screws.

Shown in the figure


.




In order to release the brake, connect the



• +: pin 2

• -: pin 5

Unscrew the motors four attachment screws and plain washers.

Shown in the figure


.

9 Fit the two guide pins in two of the motor attachment screw holes.

10 If required, press the motor out of position by fitting removal tool, motor to the motor attachment screw holes.




11 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

12 Remove the motor by gently lifting it straight out.






4 Repair


Continued

Refitting, motor axis 4


Action Note

1

DANGER

Turn off all:





2

3




.

Foundry Plus :


Tightening torque, transparent plug: 25

Nm ±10%.

Tightening torque, protection filter: 10 Nm

±10%.

xx1800000101

Protection filter

(Standard).

xx1800000102

Transparent plug

(Foundry Plus).

xx1600000576

4

5

6

In order to release the brakes, connect the


Connect to connector R2.MP4:

• +: pin 2

• -: pin 5

Fit the two guide pins in two of the motor attachment holes.



.

Shown in the figure


Fit the motor with guidance of the pins, making sure the motor pinion is properly mated to the gear of gearbox 4.






341

4 Repair


Continued

7

Action Note

Use the rotation tool in order to rotate the motor pinion when mating it to the gear!

Fit the motor, making sure the motor pinion is properly mated to the gear, axis 4.



.


Make sure the motor is turned the right direction, that is the cables facing forwards.

342

8

9

10

11

12

13

14

15

16 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

• A: Rotation tool.





4 pcs: M8 x 25, tightening torque: 24 Nm.




Shown in the figure


Perform a leak-down test if the gearbox has been drained.



.

Refill the gearbox with oil if drained.



Filling, oil on page 184 .






.

17

DANGER



.




4 Repair



Reused pinion

The pinion in the motor, axis 5, is matched with the bevel gear for axis 5. When the motor is replaced the pinion must therefore be removed from the dismounted motor and fitted onto the new motor shaft as detailed in this section.


The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below.



xx0200000204

A

B

C

Motor, axis 5

Upper arm tube

Wrist unit


Equipment, etc.

Motor

Set of shim, motor

O-ring

Grease


Art. no.



.

3HAC7941-28

21522012-430

3HAB3537-1

12340011-116

Note

Does not include pinion. Use the pinion from the motor to be replaced.

Includes o-ring 21522012-430.

Used to obtain the correct distance between motor flange and outer surface of motor pinion.



Option Foundry Plus




343


4 Repair


Continued

Equipment, etc.

Isopropanol

Mineral oil

Art. no.

11771012-208

CS 320

Removal tool, motor M10x 3HAC14972-1

Oil injector / max 500 MPa 3HAC021590-001

Press fixture (for pinion) -

Measuring tool

Guide pins M8 x 100

Guide pins M8 x 150

Power supply -

6896134-GN

3HAC15520-1

3HAC15520-2

Note

For cleaning motor pinion and motor pinion hole.

For lubrication of pinion shaft and pinion hole.


For pressing out the pinion, motor 5.

For pressing the pinion on to the new motor.

Standard toolkit


Circuit diagram -

-



24 VDC, 1.5 A




.


See chapter





1

Action Note










Axis Calibration in


.




344




4 Repair


Continued

Action




Note

Removal, motor, axis 5


1

Action


Note

2

DANGER

Turn off all:





3 Drain the oil from gearbox axis 5.

4 Remove the wrist unit.



.


Removal, wrist unit on page 260

.

5

6

7

8

Place the wrist unit safely on a workbench, in a fixture or similar.



Disconnect all connectors beneath the motor cover and remove the separate cable of the axis-

5 motor.

xx1400002580





345

4 Repair


Continued

9

10

11

Action Note


Connect to either:

- connector R4.MP5 (in the motor):

• + : pin 2

• -: pin 5

- connector R3.MP5 (on the separate cable, if not removed):

• +: pin C

• -: pin D


Fit the two guide pins in two of the motor attachment screw holes.



12

13

14

15

16

If required, press the motor out of position by fitting removal tool, motor, M10 to the motor attachment screw holes.



Always use the removal tools in pairs and diagonally!

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.


Remove the motor by gently lifting it straight out.

Keep track of the shims between the motor flange and the wrist housing.

Measure the distance between the motor flange, included eventual shims, and the outer surface of the pinion, with measuring tool.



Make a note of the distance.

Press out the pinion from the dismounted motor, with the equipment included in the oil injector kit.

Note

Replacing the complete wrist unit is detailed in section

Replacement of complete wrist unit on page 258

.



If the pinion is damaged the complete wrist unit must be replaced!

Refitting, motor, axis 5


Action Note

1

DANGER

Turn off all:





2 Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.




346




4 Repair


Continued

3

Action

Clean the pinion and the pinion hole in the motor, with isopropanol.

Note



Replacing the complete wrist unit is detailed in section

Replacement of complete wrist unit on page 258

.

Note

If the pinion is damaged the complete wrist unit must be replaced!

4

5

6

7

8

9

10

11

12

13

14

15

16

17

Apply a thin film of mineral oil to the pinion shaft and the pinion hole in order to make the pinion run smoothly and to achieve an even friction torque when assembling the pinion.



Place the motor and pinion in a press fixture .

Press the pinion onto the new motor and check the pressing force.

For an axis diameter of 15.5 mm, use min.

pressing force: 18.5 kN and max. pressing force: 39.5 kN.

If the pressing force is outside the given range or if the pinion "jumps" in bit by bit, it must be dismounted, checked, cleaned and oiled before it is assembled once again!

Measure the distance between the motor flange and the outer surface of the pinion with the measuring tool.

Modify the distance with shims in order to obtain the same distance as measured when dismounting the old motor (+ 0-0,05 mm).



In order to release the brake, connect the 24

VDC power supply.

Connect to either:

- connector R4.MP5 (in the motor):

• +: pin 2

• -: pin 5

- connector R3.MP5 (on the separate cable, if not removed):

• +: pin C

• -: pin D




Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of axis 5.



4 pcs: M8 x 25; tightening torque: 24

Nm.


Refit the separate cable of the axis-5 motor and reconnect all connectors beneath the motor cover.







.

Refit the wrist unit.


Refitting, wrist unit on page 261 .




347


4 Repair


Continued

18

Action

Foundry Plus

Make sure that the gasket is undamaged. Also the small gasket fitted in the cover recess.

Replace if damaged.

Note

19 Foundry Plus

Make sure the washers are fitted in the gasket holes. Refit the cover, wrist unit Foundry Plus.

xx1400002579

348 xx1400002580

20

21

Refill the gear with oil.


22

DANGER





.










4 Repair




The motor axis 6 is located in the center of the wrist unit as shown in the figure below.

xx0200000222

A

B

Wrist unit

Motor, axis 6


Equipment, etc.


Spare part no.

See spare part number in


.

Art. no.

O-ring 21522012-430



Note

Includes:

• motor

• pinion

• o-ring 21522012-430



349


4 Repair


Continued

Equipment, etc.

Gasket

Gasket, cover

Removal tool, motor

M10x

Guide pins M8 x 100

Guide pins M8 x 150

Power supply

Grease


Standard toolkit

Spare part no.

3HAC048560-001 i

3HAC063071-001 ii

Art. no.

Note

Must be replaced when replacing motor

3HAC033489-001

-

3HAC14972-1

3HAC15520-1

3HAC15520-2

3HAB3537-1

12340011-116

Must be replaced when opening cover.




24 VDC, 1.5 A



Option Foundry Plus



Axis Calibration


See references to these procedures in the stepby-step instructions below.

Circuit diagram -

-

3HAC15716-1

3HAC055412-

001



.






See chapter

on page 441 .

Circuit diagram

i ii

Only fits type A motor.

See


.

Only fits type B motor.

See


.


350




4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, motor


Note

Robots with protection type Foundry Plus or Foundry Prime require special repair routines to maintain the tightness level, in addition to the procedure below, described in

Replacement of the motor axis 6 (Foundry Plus) on page 353 .

1

2

Action


Move the robot to a position where the motor in axis 6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

Note





351

4 Repair


Continued

Action Note

3

DANGER

Turn off all:





5

6

4

7

Remove the rear motor cover by unscrewing the five attachment screws.

Disconnect all connectors beneath the cover.



• +: pin 2

• -: pin 5


8 If required, press the motor out of position by fitting removal tool, motor to the motor attachment screw holes.



.


9 Lift the motor carefully to get the pinion away from the gear and disconnect the brake release voltage.


10 Remove the motor by gently lifting it straight out.



Note

Robots with protection type Foundry Plus or Foundry Prime require special repair routines to maintain the tightness level, in addition to the procedure below, described in

Replacement of the motor axis 6 (Foundry Plus) on page 353 .

1

2

3

4

5

6

Action


In order to release the brake, connect the 24

VDC power supply.

Note




• +: pin 2

• -: pin 5




Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of gearbox, axis 6.

Make sure the pinion on the motor shaft is not damaged!


Secure the motor with its four attachment screws and plain washers.

4 pcs: M8 x 25, tightening torque: 24

Nm.





4 Repair


Continued

7

8

9

10

Action



Note

Refit the cover on top of the motor with its five attachment screws.







.



11

DANGER



Replacement of the motor axis 6 (Foundry Plus)

Robots with protection type Foundry Plus require special repair routines to maintain the tightness level.

The repair must be done according to the previous repair procedure with the following additions.

1

Action

Move the robot to a position where the motor in axis 6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

Note

2

DANGER

Turn off all:









353

4 Repair


Continued

3

Action

Remove the rear motor cover by unscrewing the five attachment screws.

Note

4 Continue to remove the motor unit, according to step 6 and forwards in

Removal, motor on page 351

.

xx1500002524

• A: Motor unit

• B: Connection box

• C: Attachment screw (5 pcs)

• D: Rear motor cover

• E: Gasket

5

Note

Keep the old rear motor cover with the air nipple.


354




4 Repair


Continued

6

Action

Remove the protection strip on the gasket and mount it on the motor .

Note

7

8

Apply Mercasol 3106 on the motor end cover .


xx1500002425

• A: Attachment screw (4pcs)

Mercasol 3106

• B: Motor unit

• C: O-ring

• D: Sikaflex in screw recesses

• E: Tilt house

• F: Washer

• G: Rear motor cover

• H: Sealing

• J: Loctite 574

9

10

Apply grease on the o-ring on the motor .

Continue to refit the new motor according to section,

Refitting, motor on page 352

.

xx1400000992




355

4 Repair

4.7.1 Replacing the axis 1 gearbox

4.7 Gearboxes

4.7.1 Replacing the axis 1 gearbox


The axis 1 gearbox is located between the frame and base as shown in the figure.

xx0300000538

A

B

Gearbox, axis 1

Attachment screws, gearbox axis 1 (18 pcs)


Equipment, etc.

Gearbox

O-ring

O-ring

Sealing ring

Grease

Art. no.

For spare part no.

see:

•


.

Note

Includes:

• gearbox

• all o-rings and sealing rings

3HAB3772-54

3HAB3772-55

3HAC11581-4

3HAB3537-1

Replace if damaged!

Replace if damaged!

Replace if damaged!

For lubricating the o-rings.





4 Repair


Continued

Equipment, etc.

Support, base and gear 1

Lifting accessory, base

Lifting accessory

(chain)

Guide pins



Axis Calibration

Standard toolkit

Art. no.

3HAC15535-1

3HAC15560-1

Note

3HAC15556-1

-

3HAC15716-1

3HAC055412-001

2 pcs, M16x150.

Used for guiding the gearbox into place in the base.














1

Action




Note





357

4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, gearbox axis 1

Use this procedure to remove gearbox, axis 1.

1

2

Action


Move the robot to its most stable position, shown in the figure to the right.

Note xx0300000632

3

4

5

6

DANGER

Turn off all:




Drain the axis 1 gearbox.

Remove the complete arm system.

Unfasten the robot base from the foundation by removing the base attachment screws.

See


Detailed in section

Removal, arm system on page 250

.





7

Action

Attach the lifting accessory, base and gear

1 and the lifting tool (chain) to the gearbox and base.

Note

4 Repair



Specified in


8

CAUTION

The base and axis 1 gearbox weighs 300 kg + 200 Kg.


9

10

Lift the robot base including the axis 1 gearbox to allow the base and gear 1 support be fitted on each sides of the base.



.

Secure the support to the base and to the foundation.

Make sure the base remains in a stable position before performing any work underneath the base!

xx1000000364

A Support base (4 pcs)





359

4 Repair


Continued

11

Action

Remove the bottom plate from underneath the base in order to get access to the attachment screws.

It may be necessary to also remove the rear connector plate.

Note xx1000001385

12 Unscrew the attachment screws and remove the washers.

xx0300000612

A Bottom plate

B Rear connector plate

C Attachment screw

D Groove


360 xx0200000227

A view from below:

• A: Oil drain hose

• B: Attachment screws, gearbox axis 1, 18 pcs

• C: Washers, 3 pcs




13

Action

Remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws.

Note

4 Repair


Continued

14

CAUTION

The gearbox weighs 200 Kg.


15

16

Lift the gearbox away with the already mounted lifting tools.

Turn the gearbox, and remove the protection pipe by unscrewing two attachment screws.

Note

Move the protective pipe over to the new gearbox.

xx1000001387 xx1400000786





361

4 Repair


Continued

Refitting, gearbox axis 1

Use this procedure to refit gearbox, axis 1.

1

Action Note

Fit the support, base and gear 1 to the base.

Mounting of the support, base and gear

1 is detailed in section

Removal, gearbox axis 1 on page 358 .

2 xx1000000364

A Support base (4 pcs)

Make sure the two o-rings on the circumference of the gearbox are seated properly in their respective groove. Lubricate them with grease .



xx0200000055

• A: Guide pin

• C: O-ring 3HAB 3772-54

• D: O-ring 3HAB 3772-55

• E: Sealing ring 3HAC 11581-4


362




4 Repair


Continued

3

Action

Make sure the small o-ring around the oil hole is fitted properly!

Note

4 xx1000001392

Attach the lifting accessory, base and gear 1 and the lifting tool (chain) to the gearbox.

Specified in


.

5 xx1000001395

Fit two guide pins in two of the attachment holes in the gearbox, parallel to each other.

Specified in


.

6

CAUTION

The gearbox weighs 200 Kg.






4 Repair


Continued

7

Action

Lift the gearbox.

Make sure the guide pin in the bottom face of the gearbox is properly aligned with the base.

Note xx1000001389

8 xx1000001391

Lift gearbox axis 1 onto the guide pins and lower it carefully to its mounting position.



364




4 Repair


Continued

9

Action

Secure the gearbox with its attachment screws and washers.

Note

18 pcs, M16 x 90, 12.9 quality UN-

BRAKO.

Tightening torque: 300 Nm



before fitting.

10 Refit the cable guide in the center of gearbox

1 with its attachment screws.

xx0200000227

A view from below:

• A: Oil drain hose

• B: Attachment screws, gearbox axis 1, 18 pcs

• C: Washers, 3 pcs xx1000001393





365

4 Repair


Continued

11

Action Note

Refit the bottom plate underneath the robot base by pushing it into the groove and fitting the attachment screw.

If removed, also refit the rear connector plate.

1 screw: M6 x 8.

Note

Direct the bends on the bottom plate downwards!

12

CAUTION

The base and axis 1 gearbox weighs 300 kg

+ 200 Kg.


xx0300000612

• A: Bottom plate

• B: Rear connector plate

• C: Attachment screw

• D: Groove

13

14

15

Lift the robot base and gearbox 1 and remove the base and gear support.

Secure the base to the mounting site.

See

Orienting and securing the robot on page 78

.

Refit the complete arm system.

Detailed in section

Refitting, arm system on page 252

.

CAUTION

This is a complex task to be performed with utmost care in order to avoid injury or damage!

16 Perform a leak-down test.

17

18



See section

Performing a leak-down test on page 212 .

See


.





.



.


366




4 Repair


Continued

Action

19

DANGER



.

Note




367

4 Repair

4.7.2 Replacement of gearbox axis 2

4.7.2 Replacement of gearbox axis 2


The gearbox for axis 2 is located in the lower arm rotational center, underneath the cover.



xx0300000546

C

D

E

A

B

F

G

H

Gearbox, axis 2 (inside the frame)

Attachment hole for the locking screw, lower arm

Attachment holes inside of frame for the fixture, lower arm

Attachment holes for the fixture, lower arm

Motor, axis 2

Rear attachment screws, gearbox

Cover, axis 2

Attachment screws, cover


368




4 Repair


Continued


Equipment

Gearbox axis 2

O-ring

O-ring

Sealing, axis 2

Art. no.



3HAB3772-77

3HAB3772-73

3HAC020123-001

Note

Includes

• gearbox

• o-ring.

Does not include "Sealing, axis 2/3"!

O-ring in gearbox, 1 pc.

O-ring in the cover, axis 2, 1 pc.

Should be replaced if damaged!

A new sealing must be used on each assembly!

For lubricating o-rings.

Grease



3HAB3537-1

Fixture lower arm

Lifting tool, gearbox axis 2

3HAC020729-001

3HAC020386-001

3HAC13056-2

3HAC13056-3

Press tool, balancing device 3HAC020902-001

Hydraulic cylinder 3HAC11731-1

For guiding the gearbox.


Hydraulic pump, 80 MPa 3HAC13086-1

To be used with the press tool and the hydraulic pump, when unloading the balancing device.

To be used with the press tool and the hydraulic cylinder, when unloading the balancing device.

For guiding the sealing!

Guide pins, sealing ax 2/3,

80mm

3HAC14628-1

Guide pins, sealing ax 2/3,

100mm

Gearbox crank, axis 2

3HAC14628-2

3HAC020999-001

For guiding the sealing!

Standard toolkit


-

Used to turn the gear in correct position.



in part 2 of the Product manual.






369

4 Repair


Continued




1

Action Note










Axis Calibration in


.







The procedure below details how to remove the gearbox, axis 2.

Note

1

Action


2

DANGER

3

4

Turn off all:





Secure the lower arm with the special fixture equipment according to section

Securing the lower arm on page 292 .

Unload the balancing device shaft by using the press tool, balancing device , according to section

Unloading the balancing device using hydraulic press tool on page 313 !







4 Repair


Continued

5

6

7

8

9

Action

Drain the gearbox, axis 2.

Note

Notice! Time-consuming activity!

Detailed in section


.

Remove the motor, axis 2.

Detailed in section


.

Remove the rear attachment screws, gearbox from inside of the lower arm.

Shown in the figure

Location of gearbox on page 368 !

Remove the cover, axis 2 by unscrewing its 14 attachment screws.

Shown in the figure


Remove the front attachment screws, gearbox, shown in the figure to the right.

10

11

12 xx0300000550

• A: Front attachment screws, gearbox (32 pcs)

• B: M12 holes for pressing the gearbox out



Fit two guide pins in 180° relation to each other in the empty holes of the front gearbox attachment screws.

If required, apply two M12 screws to the holes, shown in the figure above, to press it free.

Fit the lifting tool, gearbox axis 2 to the gearbox.



13

CAUTION

The gearbox weighs 100 kg! All lifting equipment used must be sized accordingly!

14

15

Remove the gearbox axis 2 using an overhead crane or similar, with guidance from the mounted guide pins.

Remove the sealing from the lower arm.





371

4 Repair


Continued


The procedure below details how to refit the gearbox axis 2.

Action Note

1

DANGER

Turn off all:





2 Make sure the o-ring is fitted to the gearbox as shown in the figure to the right. Lightly lubricate it with grease.



3

4 xx0300000551

• A: O-ring, gearbox axis 2

Fit the lifting tool, gearbox axis 2 to the gearbox.



Fit the new sealing, axis 2/3 to the gearbox.




372




4 Repair


Continued

5

Action

Fit the guide pins, sealing axis 2/3 to the rear of the gearbox, axis 2 to hold the sealing in place.

Use the attachment holes shown in the figure to the right!

Note

Note

Do not remove the guide pins for the sealing until the rear attachment screws are secured.

6 xx0300000552

• A: Rear attachment screws, gearbox (18 pcs)

• B: Holes for the guide pins, sealing axis 2/3 on the gearbox

Fit two guide pins, M12 in 180° relation to each other in the frame, in the screw holes for the gearboxes front attachment screws.



7

8

CAUTION

The gearbox weighs 100 kg! All lifting equipment used must be sized accordingly!

Lift the gearbox to its mounting position and slide it onto the guiding pins attached in the frame, through the front attachment screw holes.

xx0300000554

• A: Attachments in the frame for the two guiding pins





373

4 Repair


Continued

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

Action Note

Align the gearbox attachment screw holes to the hole patterns in the lower arm, with help from the guide pins, sealing axis 2/3.

If necessary, use a gearbox crank to turn the gear!

Use the gearbox crank with caution! The gearbox may be damaged if the crank is inserted too far into the gear!



Fit the gearbox with guidance from the guide pins and slide it into position.

If necessary, use the front gearbox attachment screws to press the gearbox into place.

Remove the lifting tool from the gearbox.

Insert and secure 30 of the 32 front attachment screws, gearbox.


115 Nm.

Remove the guide pins, M12 and refit the two remaining screws.

Lubricate the o-ring at the sealing surface of the cover, axis 2. Replace it if damaged.



Refit the cover, axis 2 to the frame with the attachment screws, cover .

Insert and secure 16 of the 18 rear attachment screws, gearbox on the inside of the lower arm.

Shown in the figure



300 Nm.



before fitting.

Remove the guide pins, sealing axis 2/3, and tighten the two remaining screws as detailed above.

Refit the motor.

Shown in the figure



Detailed in section

Refitting, motor on page 328 .

Detailed in section


.



Detailed in section

Changing oil, axis-

2 gearbox on page 177 .



.

Remove the fixture, lower arm.

Remove the locking screw, lower arm, and reattach it to the fixture tool.

Refit any mechanical stops if such were removed during disassembly.

Refit any equipment to the turning disk if such was removed during disassambly.


374




4 Repair


Continued

25

Action


26

DANGER



.

Note










375

4 Repair

4.7.3 Replacement of gearbox, axis 3

4.7.3 Replacement of gearbox, axis 3


The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.

A more detailed view of the component and its position may be found in chapter

Exploded views in Product manual, spare parts - IRB 7600 .

xx0200000194

C

D

A

B

Gearbox, axis 3

Motor, axis 3

Upper arm

Attachment screws, M12x60 quality Gleitmo (24 pcs)


Equipment, etc.

Gearbox

Art. no.

Note



Includes

• gearbox

• o-ring.

Does not include the sealing, axis 2/3!





Equipment, etc.

O-ring

Grease

Sealing, axis 3

Mechanical stop axis

3


Bolt, M16x60 (for mechanical stop axis

3)

Lifting accessory RV2

Lifting eye M12



Guide pins, sealing ax

2/3, 80mm

Guide pins, sealing ax

2/3, 100mm

Standard toolkit



Axis Calibration






377

4 Repair


Continued

Art. no.

3HAB3772-68

3HAB3537-1

3HAC17212-1

3HAC12708-1

Note

1 pc on the gearbox.

Replace if damaged.

For lubricating the o-rings.

A new sealing must be used on each assembly!

Used to secure the upper arm. Use attachment screws 3HAB3409-86

(M16 x 60).

3HAA1001-186

3HAB3409-86

3HAC13698-1

3HAC14457-3

3HAC13056-3

For lifting the gearbox.

-

3HAC13056-4

3HAC14628-1

3HAC14628-2

3HAC15716-1

3HAC055412-001


Use guides in pairs!















4 Repair


Continued




1

Action Note










Axis Calibration in


.







The procedure below details how to remove gearbox, axis 3.

1

Action


Note

2

DANGER

3

Turn off all:





Secure the upper arm in a horizontal position using round slings.




378




4 Repair


Continued

4

Action

Remove the motor, axis 3 .

Note

Detailed in section


.

Note

When removing the motor axis 3, the brake on axis

3 is released. Make sure the upper arm is secured and disabled to move!

5

6

7

8

9

10

Remove the upper arm .

Detailed in section

Removal, upper arm on page 268 .

Remove the sealing, axis 2/3 between the gearbox and lower arm.

Place the upper arm safely on a workbench, in a fixture or similar.

On reassembly a new sealing must be used! Art.

no. is specified in


Remove the attachment screws, gearbox.

Shown in the figure


Fit the two guide pins in 180° relation to each other in the gearbox attachment screw holes.



Fit the Lifting accessory RV2 according to figure.

xx0900000113





379

4 Repair


Continued

11

Action Note

If required, use screws in the holes

(A) shown in the figure to the right to press the gearbox free.



12

CAUTION

The gearbox weighs 60 kg! All lifting accessories used must be sized accordingly!

xx0200000201

• A: M12 holes for pressing the gearbox out

• B: Attachment screw holes, gearbox - upper arm

• C: Attachment screw holes, gearbox - lower arm

13 Remove the gearbox, with guidance from the guide pins, using an overhead crane or similar.


The procedure below details how to refit gearbox, axis 3.

Action Note

1

DANGER

Turn off all:





2 Turn the upper arm in such a position that the gear mating surface faces upwards.





4 Repair


Continued

3

Action Note

Fit two guide pins in 180° relation to each other in the holes in the upper arm, used for the gearbox attachment screws.



4

CAUTION

The gearbox weighs 60 kg! All lifting accessories used must be sized accordingly!

5 Fit the lifting accessory RV2 according to figure.

xx0900000113

6 Make sure the o-rings are fitted to the gearbox. Apply grease to the o-rings to make sure they stick in their grooves during assembly.

Replace if damaged!



7 Lift the gearbox to its mounting position.

xx0200000173





381


4 Repair


Continued

8

9

10

11

12

13

14

Action Note

Turn the gearbox to align the attachment screw holes with those in the upper arm.

Fit the gearbox onto the guide pins and slide it into position.

Make sure the o-rings are seated properly and the gearbox correctly oriented!

Remove the lifting tool.

Secure the gearbox with 22 of the 24 gearbox attachment screws.

Remove the guide pins and tighten the remaining two screws.

Refit the upper arm with a new sealing, axis 2/3 .

Refit the motor.


24 pcs: M12 x 60.




before fitting.


page 376 .

Required equipment on

Detailed in section

Refitting, upper arm on page 270 .

Detailed in section

Refitting, motor on page 335 .



Calibrating with Axis

Calibration method on page 401

.



.

15

DANGER



382




4 Repair


4.7.4 Replacement of gearbox, axis 6


The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.

xx0200000219

A

B

C

-

D

Gearbox, axis 6

Attachment screws and washers, gearbox (18 pcs)

Oil plug, draining

Oil plug, filling

O-ring (not shown in figure)


Equipment, etc.

Gearbox

Washers

O-ring



Article number



.

3HAA1001-172

3HAB3772-58

Note

Includes o-ring

Not included in gearbox!

Replace when damaged.

Must be replaced when reassembling gearbox.


383


4 Repair


Continued

Equipment, etc.

O-ring

O-ring

O-ring

Grease

Flange sealant

Standard toolkit

Article number

3HAB3772-57

3HAB3772-64

3HAB3772-61

3HAB3537-1

-

12340011-116

Calibration Pendulum toolkit 3HAC15716-1

Calibration tool box, Axis

Calibration

3HAC055412-001

Note

For type 2 of the gearbox.

164.7x3.53



150.0x2.0



12 pcs, 13.1x1.6



Loctite 574












1

Action




Note


384




4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, gearbox

The procedure below details how to remove gearbox, axis 6.

1

Action


Note

2

DANGER

Turn off all:





3

4

5

Drain the oil from gearbox, axis 6.



.

Remove the turning disc .


Removing, turning disk on page 255

.

Remove the gearbox by unscrewing its attachment screws .

Shown in the figure


.





385

4 Repair


Continued

6

Action

If required, apply M8 screws to the holes shown in the figure beside to press the gearbox out.

Note

Foundry Plus:

Remove old Loctite 574 flange sealant residues and other contamination from the contact surfaces.

xx0200000220

• A: M8 holes for pressing out the gearbox

7 Remove the gearbox axis 6 by lifting it out carefully.

xx1400001123

Be careful not to damage the motor pinion!

Refitting, gearbox

The procedure below details how to refit gearbox, axis 6.

Action Note

1

DANGER

Turn off all:






386




4 Repair


Continued

2

Action Note

Make sure the o-ring is fitted to the rear of the gearbox. Lubricate the o-ring with grease.



.

3

4 xx0200000221


Release the holding brake of motor axis 6.


Manually releasing the brakes on page 70

.

Foundry Plus:


xx1400001122

5 Insert the gearbox, axis 6 into the wrist unit.

6 Secure the gearbox with the attachment screws and washers.

7 Refit the turning disc .



.

Shown in the figure


Make sure the gears of the gearbox mate with the gears of the motor!

Shown in the figure


8 pcs or 18 pcs (depending on wrist version): M8 x 40, 12.9 quality Gleitmo, Tightening torque: 30 Nm.



before fitting.


Refitting, turning disk on page 256 .




387


4 Repair


Continued

8

9

10

Action

Perform a leak-down test .



11

DANGER



.

Note


Performing a leakdown test on page 212 .


Changing oil, axis-

6 gearbox on page 189

.






.

388




5 Calibration

5.1.1 Introduction and calibration terminology

5 Calibration

5.1 Introduction to calibration

5.1.1 Introduction and calibration terminology

Calibration information

This chapter includes general information about the recommended calibration methods and also the detailed procedures for updating the revolution counters, checking the calibration position etc.

Detailed instructions of how to perform Axis Calibration are given on the

FlexPendant during the calibration procedure. To prepare calibration with Axis

Calibration method, see


Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools.

Calibration terminology

Term

Calibration method

Synchronization position

Calibration position

Standard calibration

Fine calibration

Reference calibration

Update revolution counter

Synchronization mark

Definition

A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines.

Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.

Known position of the complete robot that is used for calibration of the robot.

A generic term for all calibration methods that aim to move the robot to calibration position.

A calibration routine that generates a new zero position of the robot.

A calibration routine that in the first step generates a reference to current zero position of the robot. The same calibration routine can later on be used to recalibrate the robot back to the same position as when the reference was stored.

This routine is more flexible compared to fine calibration and is used when tools and process equipment are installed.

Requires that a reference is created before being used for recalibrating the robot.

Requires that the robot is dressed with the same tools and process equipment during calibration as during creation of the reference values.

A calibration routine to make a rough calibration of each manipulator axis.

Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position.




5 Calibration

5.1.2 Calibration methods

5.1.2 Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied by ABB.

Types of calibration

Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration position.

Standard calibration data is found on the SMB

(serial measurement board) or EIB in the robot.

For robots with RobotWare 5.04 or older, the calibration data is delivered in a file, calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position.

Axis Calibration or Calibration Pendulum i

Levelmeter calibration

(alternative method)

Absolute accuracy calibration (optional)

Based on standard calibration, and besides positioning the robot at synchronization position, the Absolute accuracy calibration also compensates for:

• Mechanical tolerances in the robot structure

• Deflection due to load

Absolute accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot.

Absolute accuracy calibration data is found on the SMB (serial measurement board) in the robot.

For robots with RobotWare 5.05 or older, the absolute accuracy calibration data is delivered in a file, absacc.cfg, supplied with the robot at delivery. The file replaces the calib.cfg file and identifies motor positions as well as absolute accuracy compensation parameters.

A robot calibrated with absolute accuracy has a sticker next to the identification plate of the robot.

To regain 100% absolute accuracy performance, the robot must be recalibrated for absolute accuracy!

CalibWare xx0400001197 i

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.


If no data is found related to standard calibration, Calibration Pendulum is used as default.


390




5 Calibration


Continued

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).

Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II

• Reference calibration

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum , which describes the method and the different routines further.

Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 6650S and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.

The following routines are available for the Axis Calibration method:

• Fine calibration

• Update revolution counters

• Reference calibration

The calibration equipment for Axis Calibration is delivered as a toolkit.

An introduction to the calibration method is given in this manual, see


The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant. You will be guided through the calibration procedure, step by step.

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.

This method may, after calibration, require modifications in the robot program and is therefore not recommended.

The calibration equipment (Levelmeter 2000) for levelmeter calibration is ordered as separate parts for each robot, and includes the Operating manual - Levelmeter

Calibration , which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute

Accuracy calibration is used as a TCP calibration. The CalibWare tool guides through the calibration process and calculates new compensation parameters.

This is further detailed in the Application manual - CalibWare Field 5.0

.

If a service operation is done to a robot with the option Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance.




391


5 Calibration


Continued

For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in the section


.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum , which describes the method and the different routines further.

392




5 Calibration

5.1.3 When to calibrate

5.1.3 When to calibrate

When to calibrate

The system must be calibrated if any of the following situations occur.

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.

The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors or parts of the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See


. This will occur when:

• The battery is discharged

• A resolver error occurs

• The signal between a resolver and measurement board is interrupted

• A robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller are connected at the first installation.

The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot is changed, it needs to be recalibrated for new resolver values.

If the robot has absolute accuracy calibration, it needs to be calibrated for new absolute accuracy.




393

5 Calibration

5.2.1 Synchronization marks and synchronization position for axes

5.2 Synchronization marks and axis movement directions

5.2.1 Synchronization marks and synchronization position for axes

Introduction

This section shows the position of the synchronization marks and the synchronization position for each axis.

Synchronization marks, IRB 6650S

The figure shows IRB 6600, but the scales and their positions are the same.

xx0200000176

B2

C1

C2

A1

A2

B1

D

E

F

Synchronization mark, axis 1 (early design)

Synchronization mark, axis 1 (later design)





Synchronization mark, axis 4



Synchronization marks at axes 2 and 3

The synchronization marks at axes 2, 3 and 6, shown in the figure above, consist of two single marks that should be positioned opposite to one another when the robot is standing in its synchronization position. One of the marks is more narrow than the other and should be positioned within the limits of the wider mark.




5 Calibration

5.2.2 Calibration movement directions for all axes

5.2.2 Calibration movement directions for all axes

Overview

When calibrating, the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on. Positive directions are shown in the graphic below.

Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below.

Manual movement directions, 6 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




395

5 Calibration

5.3 Updating revolution counters

5.3 Updating revolution counters

Introduction

This section describes how to do a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.

1

2

3

Action Note

Select axis-by-axis motion mode.

Jog the manipulator to align the synchronization marks.

See


When all axes are positioned, update the revolution counter.

Step 2 - Updating the revolution counter with the TPU on page 397

(BaseWare 4.0).

Step 2 - Updating the revolution counter with the FlexPendant on page 398 .

Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important to make sure that axes 4 and 6 of the following mentioned manipulators are positioned correctly. The axes can be calibrated at the wrong turn, resulting in an incorrect manipulator calibration.

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 label, located either on the lower arm, underneath the flange plate on the base or on the frame.

At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated.

If one of the following mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration position will be lost due to non-integer gear ratio. This affects the following manipulators:

Manipulator variant

IRB 6650S

Axis 4

Yes

Axis 6

Yes

If the synchronization marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the synchronization marks again (try both directions, if needed).


396




5 Calibration


Continued

Step 2 - Updating the revolution counter with the TPU

Use this procedure to update the revolution counter with the TPU (BaseWare 4.0).

Note

1

Action

Press the button Miscellaneous then ENTER to select the service window.

xx0100000194

2 Select Calibration from the View menu.

The Calibration window appears.

If there is more than one unit connected to the manipulator, they will be listed in the window.

xx0100000201

3 Select the desired unit and choose Rev Counter Update from the Calib menu.

The Revolution Counter Update window appears.

xx0100000202

4

5

6

Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes.

Press OK when all axes that are to be updated are marked with an x.

CANCEL returns to the Calibration window.

Press OK again to confirm and start the update.

CANCEL returns to the Revolution Counter Update window.




397


5 Calibration


Continued

7

Action Note

At this point, it is recommended that the revolution counter values are saved to a diskette.

Not required.

8

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury!

Check the synchronization position very carefully after each update.

How to perform the check is detailed in section

Checking the synchronization position on page 414 .

Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).

1

Action

On the ABB menu, tap Calibration .

xx1500000942


398




5 Calibration


Continued

2

Action

All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

xx1500000943

3 This step is valid for RobotWare 6.02 and later.

Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration.

Tap Manual Method (Advanced) .


3HAC020993-001 Revision: Z xx1500000944



399

5 Calibration


Continued

4

Action

A screen is displayed, tap Rev. Counters .

400 en0400000771

5

6

7

Tap Update Revolution Counters...

.

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

Select the axis to have its revolution counter updated by:

• Ticking in the box to the left

• Tapping Select all to update all axes.

Then tap Update .

A dialog box is displayed, warning that the updating operation cannot be undone:

• Tap Update to proceed with updating the revolution counters.

• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the selected revolution counters and removes the tick from the list of axes.

8

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury!

Check the synchronization position very carefully after each update. See

Checking the synchronization position on page 414

.




5 Calibration

5.4.1 Description of Axis Calibration

5.4 Calibrating with Axis Calibration method

5.4.1 Description of Axis Calibration

Instructions for Axis Calibration procedure given on the FlexPendant


This manual contains a brief description of the method, additional information to the information given on the FlexPendant, article number for the tools and images of where to fit the calibration tools on the robot.

Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis at the time. The robot axes are both manually and automatically moved into position, as instructed on the FlexPendant.

A fixed calibration pin/bushing is installed on each robot axis at delivery.

The Axis Calibration procedure described roughly:

• A removable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration, according to instructions on the

FlexPendant.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel.

WARNING

The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.

• During the calibration procedure, RobotWare moves the robot axis chosen for calibration so that the calibration tools get into contact. RobotWare records values of the axis position and repeats the coming-in-contact procedure several times to get an exact value of the axis position.

WARNING

Risk of pinching! The contact force for large robots can be up to 150 kg.

Keep a safe distance to the robot.

• The axis position is stored in RobotWare with an active choice from the operator.




401


5 Calibration

5.4.1 Description of Axis Calibration

Continued

Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the beginning of the procedure on the FlexPendant.

Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling or equipment fitted to the robot.

Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the robot is dressed with tools, process cabling or other equipment.

If calibrating the robot with reference calibration there must be reference values created before repair is made to the robot, if values are not already available.

Creating new values requires possibility to move the robot. The reference values contain positions of all axes, torque of axes and technical data about the tool installed. A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.


When reference calibration is performed, the robot is restored to the status given by the reference values.

Note

Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Validation

When calibrating the robot with the reference calibration routine, the robot must be dressed with the same tools, process cabling and any other equipment as when the reference values were created.

In the mentioned routines, it is also possible to validate the calibration data.

Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to its calibration position during the calibration procedure.

In order for the axis to be able to be moved to calibration position, or in order for getting proper access to the calibration bushing, other axes might need to be jogged to positions different from 0 degrees. Information about which axes are allowed to be jogged will be given on the FlexPendant. These axes are marked with Unrestricted in the FlexPendant window.

402




5 Calibration

5.4.2 Calibration tools for Axis Calibration

5.4.2 Calibration tools for Axis Calibration

Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance, durability and safety in case of accidental damage.

The calibration tool will eventually break from fatigue after longer period of use and then needs to be replaced. There is no risk for bad calibrations as long as the calibration tool is in one piece.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from

ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel.

Equipment, etc.


Axis Calibration

Article number

3HAC055412-001

Note



Examining the calibration tool

Check prior to usage

Before using the calibration tool, make sure that the tube insert, the plastic protection and the steel spring ring are present.

WARNING

If any part is missing or damaged, the tool must be replaced immediately.

xx1500001914

A

B

C

Tube insert

Plastic protection

Steel spring ring





403

5 Calibration

5.4.2 Calibration tools for Axis Calibration

Continued

Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following measures should be checked.

• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on calibration tool size).

• Straightness within 0.005 mm.

xx1500000951

A Outer diameter

Identifying the calibrating tools

It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below.

2

Note

1

The tool identifier is NOT delivered from ABB, it is a customized solution.

Action

It is possible to use any RFID solution, with the correct dimensions. ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices (13.56 Mhz) according to ISO

14443 or ISO 15693.

Note

Note

The maximum dimensions on the RFID chip must not exceed Ø7.9 mm x 8.0 mm, Ø5.9 mm x 8.0

mm or Ø3.9 mm x 8.0 mm (depending on calibration tool size).

There is a cavity on one end of the calibration tool in which the RFID chip can be installed.

Install the RFID chip according to supplier instructions.

Install the chip in flush with the tool end.

404




5 Calibration

5.4.3 Installation locations for the calibration tools

5.4.3 Installation locations for the calibration tools

Location of fixed calibration items

This section shows how the robot is equipped with items for installation of calibration tools for Axis Calibration (fixed calibration pins and/or bushings).

Installed calibration tools are not shown.

A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows.

Spare parts xx1500000912

The fixed calibration pin for axis 1 is installed on a removable tower. The tower will need to be removed if electronic position switches are fitted to the robot. Keep the tower in a safe location for future recalibration needs and mark it with robot serial number to ensure that the correct one is refitted.

When calibration is not being performed, a protective cover and an o-ring should always be installed on the fixed calibration pin as well as a protective plug, included a sealing, in the bushing. Replace damaged parts with new, if needed.

Spare part

Protection cover and plug set

Article number

3HAC056806-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.




405

5 Calibration

5.4.4 Axis Calibration - Running the calibration procedure

5.4.4 Axis Calibration - Running the calibration procedure

Required tools

The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance, durability and safety in case of accidental damage.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from

ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel.

Equipment, etc.

Calibration tool box, Axis

Calibration

Article number

3HAC055412-001

Note



Required consumables

Consumable

Clean cloth

Spare parts

Spare part

Protection cover and plug set

-


Article number

3HAC056806-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.

Overview of the calibration procedure on the FlexPendant


Use the following list to learn about the calibration procedure before running the

RobotWare program on the FlexPendant. It gives you a brief overview of the calibration procedure sequence.

After the calibration method has been called for on the FlexPendant, the following sequence will be run.

1 Choose calibration routine. The routines are described in

Routines in the calibration procedure on page 402

.

2 Choose which axis/axes to calibrate.

3 The robot moves to synchronization position.

4 Validate the synchronization marks.

5 The robot moves to preparation position.

6 Remove the protective cover from the fixed pin and the protection plug from the bushing, if any, and install the calibration tool.





5 Calibration


Continued

7 The robot performs a measurement sequence by rotating the axis back and forth.

8 Remove the calibration tool and reinstall the protective cover on the fixed pin and the protection plug in the bushing, if any.

9 The robot moves to verify that the calibration tool is removed.

10 Choose whether to save the calibration data or not.

Calibration of the robot is not finished until the calibration data is saved, as last step of the calibration procedure.

Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.

Action Note

1

DANGER

While conducting the calibration, the robot needs to be connected to power.

Make sure that the robots working area is empty, as the robot can make unpredictable movements.

2 Wipe the calibration tool clean.

Use a clean cloth.

Note

The calibration method is exact. Dust, dirt or color flakes will affect the calibration value.

Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.

1

Action

On the ABB menu, tap Calibration .

Note xx1500000942





407

5 Calibration


Continued

2

Action

All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

Note xx1500000943

3 Calibration method used at factory for each axis is shown, as well as calibration method used for the robot during last field calibration.

Tap Run Calibration Method . The software will automatically call for the procedure for the valid calibration method.

The FlexPendant will give all information needed to proceed with Axis

Calibration.

xx1500000944

4 Follow the instructions given on the FlexPendant.

A brief overview of the sequence that will be run on the FlexPendant is given in

Overview of the calibration procedure on the FlexPendant on page 406 .

Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished, the RobotWare program needs to be started again. Use this procedure to take required action.

Situation Action

The three-position enabling device on the

FlexPendant has been released during robot movement.

Press and hold the three-position enabling device and press Play .





5 Calibration


Continued

Situation Action

The RobotWare program is terminated with

PP to Main .

Remove the calibration tool, if it is installed, and restart the calibration procedure from the beginning. See

Starting the calibration procedure on page 407

.

If the calibration tool is in contact the robot axis needs to be jogged in order to release the calibration tool. Jogging the axis in wrong direction will cause the calibration tool to break. Directions of axis movement is shown in

Calibration movement directions for all axes on page 395

Axis Calibration with SafeMove option

To be able to run Axis Calibration SafeMove needs to be unsynchronized. The Axis

Calibration routine recognizes if the robot is equipped with SafeMove and will force

SafeMove to unsynchronize automatically.

However, SafeMove may generate other warning messages anytime during the

Axis Calibration routine.

Safety controller not synchronized - SafeMove message

1

Action

SafeMove generates the message "Safety controller not synchronized".

Note

2

3 xx1500002480

Confirm unsynchronized state by pressing Acknowledge to continue Axis Calibration procedure.

Restart Axis Calibration procedure by pressing

Play .





409

5 Calibration


Continued

Unsynchronized speed exceeded - SafeMove message while saving robot data

1

Action

SafeMove generates the message "Unsynchronized speed exceeded" while saving robot data.

Note xx1500002481

2

3

Press Acknowledge to continue Axis Calibration procedure.


Play .

Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine

1

Action

SafeMove generates the message "Unsynchronized time limit expired" (anytime).

Note

2

3 xx1500002482

Press OK to continue Axis Calibration procedure.


Play .


410




5 Calibration


Continued

After calibration

1

2

Action

Check the o-ring on the fixed calibration pin.

Replace if damaged or missing.

Reinstall the protective cover on the fixed calibration pin on each axis, directly after the axis has been calibrated.

Replace the cover with new spare part, if missing or damaged.

Note

3 Reinstall the protective plug and sealing in the bushing on each axis, directly after the axis has been calibrated. Ensure that the sealing is not damaged.

Replace the plug and the sealing with new spare part, if missing or damaged.

xx1600002102

Protection cover and plug set:

3HAC056806-001.

xx1500000952

Protection cover and plug set:

3HAC056806-001.




411

5 Calibration

5.5 Calibrating with Calibration Pendulum method

5.5 Calibrating with Calibration Pendulum method

Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools.

412




5 Calibration

5.6 Verifying the calibration

5.6 Verifying the calibration

Introduction

Always verify the results after calibrating any robot axis to verify that all calibration positions are correct.

Verifying the calibration

Use this procedure to verify the calibration result.

1

2

3

4

Action Note

Run the calibration home position program twice.

Do not change the position of the robot axes after running the program!

See

Checking the synchronization position on page 414 .

Adjust the synchronization marks when the calibration is done, if necessary.



Write down the values on a new label and stick it on top of the calibration label.

The label is located on the lower arm.

Remove any calibration equipment from the robot.




413

5 Calibration

5.7 Checking the synchronization position

5.7 Checking the synchronization position

Introduction

Check the synchronization position of the robot before beginning any programming of the robot system. This may be done:

• Using a MoveAbsJ instruction with argument zero on all axes.

• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction on the TPU, S4Cplus

Use this procedure to create a program that runs all the robot axes to their synchronization position.

Note

1

Action

Create the following program:

MoveAbsJ [[0,0,0,0,0,0], [9E9,

9E9,9E9,9E9,9E9,9E9]]

\NoEOffs, v1000, z50, Tool0

2

3

Run the program in manual mode.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See


and


Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their synchronization position.

1

2

3

4

Action

On ABB menu tap Program editor .

Create a new program.

Use MoveAbsJ in the Motion&Proc menu.

Create the following program:

MoveAbsJ [[0,0,0,0,0,0],

[9E9,9E9,9E9,9E9,9E9,9E9]]

\NoEOffs, v1000, fine, tool0

Note

5

6

Run the program in manual mode.


See


and



414




5 Calibration

5.7 Checking the synchronization position

Continued

Using the jogging window on the TPU, S4Cplus

Use this procedure to jog the robot to synchronization position of all axes.

1

Action

Open the Jogging window.

Illustration/Note xx0100000195

2 Select running axes-by-axes.

xx0100000196

3

4

Manually run the robot axes to a position where the axis position value read on the

TPU, is equal to zero.


See


and


.

Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.

1

2

3

4

5

Action

On the ABB menu, tap Jogging .

Note

Tap Motion mode to select group of axes to jog.

Tap to select the axis to jog, axis 1, 2, or

3.

Manually run the robots axes to a position where the axis position value read on the

FlexPendant, is equal to zero.


See


and





415


6 Decommissioning

6.1 Environmental information


6.1 Environmental information

Symbol

The following symbol indicates that the product must not be disposed of as common garbage. Handle each product according to local regulations for the respective content (see table below).

xx1800000058

Hazardous material

The table specifies some of the materials in the product and their respective use throughout the product.

Dispose components properly according to local regulations to prevent health or environmental hazards.

Material

Batteries, NiCad or Lithium

Copper

Cast iron/nodular iron

Steel

Neodymium

Plastic/rubber

Oil, grease

Aluminium

Nickel

Example application

Serial measurement board

Cables, motors

Base, lower arm, upper arm

Gears, screws, base frame, and so on.

Brakes, motors

Cables, connectors, drive belts, and so on.

Gearboxes

Covers, synchronization brackets

Turning disc (foundry)

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration must be carried out under controlled conditions in accordance with local regulations.




417



6.1 Environmental information

Continued

Also note that:

• 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.

418





6.2 Scrapping of robot

6.2 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries:

• Always remove all batteries. If a battery is exposed to heat, for example from a blow torch, it will explode.

• Always remove all oil/grease in gearboxes. If exposed to heat, for example from a blow torch, the oil/grease will catch fire.

• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed.




419


6.3 Decommissioning of balancing device

6.3 Decommissioning of balancing device

General

There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.

The device must be dismantled by a decommissioning company.


Equipment

Standard toolkit

Cutting torch


-

Art. no.

Note



.

For opening housing and cutting coils


DANGER

Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!

Action on field, decommissioning

The procedure below details the actions to perform on field, when the balancing device is to be decommissioned.

1

2

Action Note

Remove the balancing device from the robot.

Detailed in section

Removal, balancing device on page 309

.

Send the device to a decommissioning company.

Make sure the decommissioning company is well informed about the stored energy built up by high tensioned compression springs and that the device contains some grease.

The following procedure contains useful information about decommissioning.


420





6.3 Decommissioning of balancing device

Continued

Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact

ABB Robotics for further consultation.

Action Note

1

DANGER

There is stored energy built up by high tensioned compression springs inside the balancing device! The device also contains some grease!

2 Place the device on a workbench or similar. Make sure it is clamped in position with a vice or similar.

3 Open a hole in the side of the housing as shown in the figure.

Use a cutting torch. The measurements shown below are maximum values!

xx0400000698

4 Cut the coils of the three springs inside the housing as specified below:

• Outer spring: cut at least five coils!

• Middle spring: cut at least four coils!

• Inner spring: cut at least four coils!

Use a cutting torch.

5 Double-check the number of coils cut and make sure all the tension in the springs is removed.




421


7 Robot description

7.1 Type A vs type B motors


7.1 Type A vs type B motors

Identifying the motor visually

Type B motors include evacuation on the motor flange to indicate failure of primary sealing between the gearbox and the motor. Robots with protection type Foundry

Plus have a sight glass installed in the evacuation holes.

Use the images to identify which type of motor is installed on each robot axis.

Type A motor Type B motor

1

2

3 xx1500001058

No evacuation on type A motors.

xx1500001057

The type B motor include evacuation on the motor flange.

Identifying the motor by article number

Use the table to identify which type of motor is installed on each robot axis by article number. The article numbers specified are found in WebConfig.

Contact ABB Service for further assistance regarding which motor type is installed on the robot, if needed.

Robot axis

4

Note

The article numbers in the table can not be used for ordering spare parts. The numbers are only used for identification of installed motors.

See Product manual, spare parts - IRB 6650S for spare part numbers.

Article number

Type A motor

3HAC057550-001

3HAC057551-001

3HAC057546-001

3HAC058883-001 (Foundry Prime)

3HAC057547-001


Article number

Type B motor

3HAC062343-001

3HAC062344-001

3HAC062345-001

N/A

3HAC062346-001

N/A




423



7.1 Type A vs type B motors

Continued

Robot axis

5

6

Article number

Type A motor

3HAC057548-001


3HAC057549-001


Article number

Type B motor

3HAC062335-001

N/A

3HAC062348-001

N/A

Interchangeable parts

Use the table to see if type A and type B motors are interchangeable on each robot axis.

3

4

1

2

5

6

Robot axis Motor replacement from type A to type B

Fully interchangeable.






Requirements/notes for replacing type A motor with type B motor

424




8 Spare part lists

8.1 Spare part lists and illustrations

8 Spare part lists

8.1 Spare part lists and illustrations

Location

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.myportal.abb.com

.




425


9 Reference information

9.1 Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.




427


9.2 Applicable standards

9.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased out or replaced standards are removed from the list when needed.

Standards, EN ISO

The product is designed in accordance with the requirements of:

Standard

EN ISO 12100:2010

EN ISO 13849-1:2015

EN ISO 13850:2015

EN ISO 10218-1:2011

ISO 9787:2013

ISO 9283:1998

Description

Safety of machinery - General principles for design - Risk assessment and risk reduction

Safety of machinery, safety related parts of control systems -

Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Robots for industrial environments - Safety requirements -Part

1 Robot

Robots and robotic devices -- Coordinate systems and motion nomenclatures

Manipulating industrial robots, performance criteria, and related test methods

Classification of air cleanliness

Ergonomics of the thermal environment - Part 1

EMC, Generic emission

EN ISO 14644-1:2015 i

EN ISO 13732-1:2008

EN 61000-6-4:2007 +

A1:2011

IEC 61000-6-4:2006 +

A1:2010

(option 129-1)

EN 61000-6-2:2005

IEC 61000-6-2:2005

EN IEC 60974-1:2012 ii

EN IEC 60974-10:2014

ii

EMC, Generic immunity

Arc welding equipment - Part 1: Welding power sources

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part

1 General requirements i ii

IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)

Only robots with protection Clean Room.

Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard

EN 614-1:2006 + A1:2009

EN 574:1996 + A1:2008

Description

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles

Safety of machinery - Two-hand control devices - Functional aspects - Principles for design






9.2 Applicable standards

Continued

Other standards

Standard

ANSI/RIA R15.06

ANSI/UL 1740

CAN/CSA Z 434-14

Description

Safety requirements for industrial robots and robot systems

Safety standard for robots and robotic equipment

Industrial robots and robot Systems - General safety requirements




429


9.3 Unit conversion

9.3 Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity

Length

Weight

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 g

1 bar

1 N

1 Nm

1 L

3.28 ft.

2.21 lb.

0.035 ounces

100 kPa

0.225 lbf

0.738 lbf-ft

0.264 US gal

39.37 in

14.5 psi

430





9.4 Screw joints

9.4 Screw joints

General

This section describes how to tighten the various types of screw joints on the IRB

6650S.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

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.

Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed. Using other types of screws will void any warranty and may potentially cause serious damage or injury.

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1 Apply lubricant to the screw thread.

2 Apply lubricant between the plain washer and screw head.

3 Screw dimensions of M8 or larger must be tightened with a torque wrench.

Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.

Lubricant

Molycote 1000 (molybdenum disulphide grease)

Article number

3HAC042472-001

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the following tables. Any special torques are specified in the repair, maintenance or installation procedure descriptions.

Any special torque specified overrides the standard torque!

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.




431



9.4 Screw joints

Continued

• Always tighten the joint by hand, and never use pneumatic tools.

• Use the correct tightening technique , that is do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10% !

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Note

A special torque specified in the repair, maintenance or installation procedure overrides the standard torque.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with allen head screws.

Note


Dimension

M5

M6

M8

M10

M12

M16

M20

M24

10

24

47

82

Tightening torque (Nm)

Class 8.8, oil-lubricated

Tightening torque (Nm) Tightening torque (Nm)



6 -

-

34

67

115

-

40

80

140

200

400

680

290

560

960

340

670

1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head screws.

Note


Dimension Tightening torque (Nm)

Class 10.9, lubricated i

28 M8


432


Class 12.9, lubricated

i

35





9.4 Screw joints

Continued

Dimension Tightening torque (Nm)

Class 10.9, lubricated i


Class 12.9, lubricated

i

M10

M12

M16

55

96

235

70

120

280

M20 460 550 i

M24 790 950

Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass .

Note


1/8

1/4

3/8

1/2

3/4

Dimension

15

20

40

70

Tightening torque Nm -

Nominal


Min.


Max.

12 8 15

10

15

30

55

20

25

50

90




433


9.5 Weight specifications

9.5 Weight specifications

Definition

In installation, repair, and maintenance procedures, weights of the components handled are sometimes specified. 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.

Example

Following is an example of a weight specification in a procedure:

Action Note

CAUTION

The robot weighs 2275 kg.

All lifting accessories used must be sized accordingly.

434





9.6 Standard tools

9.6 Standard tools

General

All service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standard toolkit and defined in the following table.

This way, the tools required are the sum of the standard toolkit and any tools listed in the instruction.

Contents, standard toolkit

1

1

1

1

1

1

1

2

1

1

1

1

Qty Tool

Ring-open-end spanner 8-19 mm

Socket head cap 5-17 mm

Torx socket no: 20-60

Box spanner set

Rem.

Torque wrench 10-100 Nm

Torque wrench 75-400 Nm

Ratchet head for torque wrench 1/2

Hexagon-headed screw M10x100

Hex bit socket head cap no. 14 socket 40 mm L=100 mm

Hex bit socket head cap no. 14 socket 40 mm L=20 mm To be shortened to 12 mm

Hex bit socket head cap no. 6 socket 40 mm L=145 mm

Hex bit socket head cap no. 6 socket 40mm bit L=220 mm




435


9.7 Special tools

9.7 Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section


, and of special tools, listed directly in the instructions and also gathered in this section.

Basic tools

The following table specifies the tools in the basic toolkit (3HAC15571-3) that are used for the current robot model. This toolkit is necessary primary when removing and refitting the motors.

The tools are also listed directly in the instructions.

Description

Guide pins M8 x 100

Guide pins M8 x 150



Lifting tool, wrist unit





Rotation tool


Bolts M16 x 60 (for mechanical stop axis 3)


Standard toolkit (content described in section


)

1

2

2

1

2

2

2

2

Qty

2

1

2

1

1

2

Art. no.

3HAC15520-1

3HAC15520-2

3HAC15521-1

3HAC15521-2

3HAC13605-1

3HAC14459-1

3HAC15534-1

3HAC14972-1

Fits motors, axes 4, 5 and 6.

3HAC14631-1

Fits motors axes 1, 2 and 3.

3HAC17105-1

3HAC12708-1

3HAB3409-86

3HAA1001-186

3HAC15571-1

Special tools

The following table specifies the special tools required during several of the service procedures. The tools may be ordered separately and are also specified directly in concerned instructions in the product manual.

Description

Fixture lower arm

Gearbox crank, axis 2




2

2

Qty

1

1

2

Art. no.

3HAC020729-001

3HAC020999-001

3HAC022637-001

3HAC13056-2

3HAC13056-3






9.7 Special tools

Continued

Description



Guide pins, sealing ax 2/3, 100mm

Guide pins, sealing ax 2/3, 80mm

Holder for bits (Stahlwille 736/40 S 5/16")

Hydraulic cylinder


Hydraulic pump, 150 MPa (Glycerin)


Lifting accessory, base


Lifting accessory, upper arm

Lifting eye VLBG M12

Lifting eye M12

Lifting eye M16


Lifting tool, gearbox axis 2

Lifting tool (chain), Balancing device

Measuring tool

Oil injector / max 500 MPa





Press tool, balancing device shaft


Shackle, balancing device

Support, base

Tool set balancing device

3HAC14457-4

3HAC15556-1

3HAC020386-001

3HAC020540-001

6896134-GN

3HAC021590-001

3HAC13527-1

3HAC021563-001

3HAC021600-001

3HAC020902-001

3HAC17129-1

3HAC12475-1

3HAC020997-001

3HAC15535-1

3HAC021984-001

Art. no.

3HAC13056-4

3HAC13120-5

3HAC14628-2

3HAC14628-1

3HAC029090-001

3HAC11731-1

3HAC13086-1

3HAC021563-012

3HAC022643-001

3HAC15560-1

3HAC15607-1

3HAC15994-1

3HAC16131-1

3HAC14457-3

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

2

1

1

1

1

1

1

1

2

Qty

1

2

1

Tools that may be rented

The following table specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual.

The special tools are also listed directly in the instructions.

Description

Lifting tool, lower arm

Art. no.

3HAC14691-1

Note

Includes

• Guidances, 3HAC14446-1




437



9.7 Special tools

Continued

Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating the robot with the alternative method, Levelmeter Calibration.

Note Description

Angle bracket

Calibration bracket

Calibration tool ax1

Levelmeter 2000 kit

Measuring pin

Sensor fixture

Sensor plate

Sync. adapter

Art. no.

68080011-LP

3HAC13908-9

3HAC13908-4

6369901-347

3HAC13908-5

68080011-GM

3HAC0392-1

3HAC13908-1

Includes one sensor.

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.

Always use the same calibration method as used at the factory.



Description


Art. no.

3HAC15716-1

Note


Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating the robot with the Axis Calibration method.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.

Always use the same calibration method as used at the factory.



Description Art. no.


3HAC055412-

001

Note




438





9.7 Special tools

Continued

Oil exchange equipment

The following table specifies the recommended equipment for oil exchange.

Description


Art. no.

3HAC021745-001

Note

Includes:

• Vacuum pump with regulator, hose and coupling

• Couplings and adapters

• Pump (manual) with hose and coupling

• Graduated measuring glass

• Oil gun

• User instructions.




439


9.8 Lifting accessories and lifting instructions

9.8 Lifting accessories and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure.

The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.

This implies that the instructions delivered with the lifting accessories should be stored for later reference.

440




10 Circuit diagram

10.1 Circuit diagrams


10.1 Circuit diagrams

Overview

The circuit diagrams are not included in this manual, but are available for registered users on myABB Business Portal, www.myportal.abb.com

.

See the article numbers in the tables below.

Controllers

Product

Circuit diagram - IRC5

Circuit diagram - IRC5 Compact

Article numbers for circuit diagrams

3HAC024480-011

3HAC049406-003

Circuit diagram - IRC5 Panel Mounted Controller

3HAC026871-020

Circuit diagram - Euromap 3HAC024120-004

Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product

Circuit diagram - IRB 120

Circuit diagram - IRB 140 type C








Circuit diagram - IRB 1600/1660




Circuit diagram - IRB 4400/4450S


Circuit diagram - IRB 6400RF

Circuit diagram - IRB 6600 type A

Circuit diagram - IRB 6600 type B




3HAC031408-003

3HAC6816-3

3HAC025611-001

3HAC028647-009

3HAC036446-005

3HAC025691-001

3HAC025691-001

3HAC046307-003

3HAC2800-3

3HAC021351-003

3HAC039498-007

3HAC6670-3

3HAC029570-007

3HAC9821-1

3HAC029038-003

3HAC8935-1

3HAC13347-1

3HAC025744-001

3HAC13347-1

3HAC025744-001


441



10.1 Circuit diagrams

Continued

Product


Circuit diagram - IRB 6620 / IRB 6620LX


Circuit diagram - IRB 6650S





3HAC025090-001

3HAC025090-001

3HAC025744-001

3HAC13347-1

3HAC025744-001

3HAC025744-001

3HAC029940-001

3HAC043446-005

3HAC13347-1

3HAC025744-001

3HAC050778-003

3HAC056159-002

Circuit diagram - Product.ProductName

Circuit diagram - IRB 910SC

Use the correct circuit diagram (IRB 6600, IRB 6650 and IRB 6650S)

The cable harness of the robot is available in two different designs. Either the cabling is divided between the upper and lower arm, or not. Accordingly there are also two different versions of the circuit diagram. Decide which circuit diagram is valid for the robot by checking the article number for the cable harness.

442





10.2.1 Validity of circuit diagram 3HAC025744-1

10.2 Circuit diagram 3HAC 025744-001

10.2.1 Validity of circuit diagram 3HAC025744-1

Is this circuit diagram valid for your robot?

The validity of the circuit diagram depends on which cable harness is fitted to the robot.

Check the article number of the cable harness fitted to the robot and see page 3 of the circuit diagram in order to determine if the diagram is valid for the harness or not.

Where to find the article number

Label on the cable harness

Action

The label is located at the connectors in the base.

Remove the rear cover plate to see the label.

WebConfig




443


10.3.1 Validity of circuit diagram 3HAC13347-1

10.3 Circuit diagram 3HAC 13347-1

10.3.1 Validity of circuit diagram 3HAC13347-1

Is this circuit diagram valid for your robot?

The validity of the circuit diagram depends on which cable harness is fitted to the robot.

Check the article number of the cable harness fitted to the robot.

Where to find the article number

Label on the cable harness

WebConfig -

Action

The label is located at the connectors in the base.

Remove the rear cover plate to see the label.

This circuit diagram is valid for the following cable harness assemblies:

Robot

IRB 6600

IRB 6650, IRB 6650S

IRB 7600

Cable harness

3HAC 14940-1

3HAC 16331-1

3HAC 14940-1

Revision all all revision 0-2

For remaining cable harness assemblies, see section

Validity of circuit diagram

3HAC025744-1 on page 443 .

444




Index

Index

A

Absolute Accuracy, calibration, 391

additional mechanical stop location, 163

aluminum

disposal, 417

ambient humidity

operation, 55 storage, 55

ambient temperature


assembly instructions, 51

assessment of hazards and risks, 22

Axis Calibration, 401

calibration tool

article number, 403, 406

examining, 403

installation position, 405

overview of method, 401

procedure on FlexPendant, 406

protective cover and protection plug, 405–406

B

balancing device, replacement, 306

balancing device bearing, replacement, 303

base plate

guide pins, 73 securing, 73

batteries

disposal, 417

handling, 39

battery

replacing, 192, 296

battery pack

replacing, interval, 129

battery shutdown

service routine, 192, 296

brake release, 70

brake release board, replacement, 299

brakes

testing function, 38

buttons for brake release, 70

C

cabinet lock, 27, 33

cable harness axes 1-6, replacement, 219

cable harness axes 1-4, replacement, 232

cabling, robot, 119

cabling, robot axes 1-4, 233

cabling, robot axes 5-6, 242

cabling axis 5, replacement, 246

cabling between robot and controller, 119

calibrating

robot, 401

roughly, 396

calibrating robot, 401

calibration

Absolute Accuracy type, 390

alternative method, 391

Levelmeter calibration, 391

rough, 396

standard type, 390

verification, 413

when to calibrate, 393




calibration, Absolute Accuracy, 391

calibration manuals, 392

calibration marks, 394

calibration position

jogging to, 415 jogging to, TPU, 415

scales, 394 calibration scales, 394

CalibWare, 390

carbon dioxide extinguisher, 24

cast iron

disposal, 417

changing oil

axis 1, 174

cleaning, 199

climbing on robot, 27

Cold environments, 124

complete arm system, replacement, 248

connecting the robot and controller, cabling, 119

connection

external safety devices, 28

copper

disposal, 417

D

damage to additional mechanical stop, 163

damage to mechanical stop, 161

danger levels, 42

dimensions

frame, 84

lower arm, 81

upper arm, 83

direction of axes, 395

E

enabling device, 32

environmental information, 417

EPS, 101

equipment on robot, 81

ESD

damage elimination, 35 sensitive equipment, 35

expected life, 131

extended working range, axis 1, 101

external safety devices, 28

extra equipment

fastener quality, 86

frame, 84

lower arm, 81 robot, 81

upper arm, 83

F

fastener quality for extra equipment, 86

fire extinguishing, 24

fitting equipment on robot, 81

FlexPendant

jogging to calibration position, 415

MoveAbsJ instruction, 414

updating revolution counters, 398

fork lift, 61

foundation

requirements, 54

frame

dimensions, 84

445

Index

G gearbox

oil change axis 1, 174

gearbox axis 1, replacement, 356




gearboxes

location of, 172

grease

disposal, 417

guide pins, base plate, 73

H hanging

installed hanging, 27

hazardous material, 417

height

installed at a height, 27

hold-to-run, 32

HRA, 22

humidity


I

information labels location, 159

inspecting

additional mechanical stop, 163

information labels, 159

mechanical stop, 161

motor seal, 132

inspecting oil levels

axis-6, 145

axis-5, 143

axis-4, 141

axis-3, 138

axis-2, 136

axis-1, 134

installation

mechanical stop axis 1, 99



installing

position switches, 107

installing equipment on robot, 81

instructions for assembly, 51

integrator responsibility, 21

intervals for maintenance, 127

L labels

robot, 44

leak-down test, 212

Levelmeter calibration, 391

lifting accessory, 434

lifting robot

with fork lift, 61

with lifting slings, 68

with roundslings, 66

lifting slings, robot, 68

lifting upper arm

attachment points for lifting accessory, 264

limitation of liability, 21

Lithium

disposal, 417

loads on foundation, 53

446


lower arm

dimensions, 81

replacement, 273

lower arm shaft, replacement, 283

lubrication

amount in gearboxes, 172 type of lubrication, 172

M magnesium

disposal, 417

maintenance schedule, 127

manually releasing brakes, 70

mechanical stop

axis 1, 99

axis 2, 102

axis 3, 104

mechanical stop location, 161

motion of axes, 59

motor axis 1, replacement, 320






motor seal

inspecting, 132


TPU, 414

N

nation specific regulations, 21

negative directions, axes, 395

neodymium

disposal, 417

NiCad

disposal, 417

nodular iron

disposal, 417

O oil

amount in gearboxes, 172

disposal, 417

type of oil, 172

oil change

axis 1, 174

safety risks, 40

oil level

gearbox axis-6, 145

gearbox axis-5, 143

gearbox axis-4, 141

gearbox axis-3, 138

gearbox axis-2, 136

gearbox axis-1, 134

operating conditions, 55

P pedestal

installed on pedestal, 27

plastic

disposal, 417

position switches

installing, 107

positive directions, axes, 395

product standards, 428

protection classes, 55



Index

protection type, 55

protective equipment, 28 protective wear, 28

R

radius, turning, 59 range of movement, 59

region specific regulations, 21

release brakes, 25

replacement

balancing device, 306

bearing, balancing device, 303

brake release board, 299

cable harness axes 1-6, 219

cable harness axes 1-4, 232

cabling axis 5, 246

complete arm system, 248

gearbox axis 1, 356

gearbox axis 2, 368

gearbox axis 3, 376

gearbox axis 6, 383

lower arm, 273

lower arm shaft, 283

motor axis 1, 320

motor axis 2, 325

motor axis 3, 331

motor axis 4, 338

motor axis 5, 343

motor axis 6, 349

turning disk, 254

upper arm, 264

wrist unit, 258

requirements on foundation, 54

responsibility and validity, 21

restricting

working range axis 1, 99, 101

working range axis 2, 102

working range axis 3, 104

revolution counters

storing on FlexPendant, 398

storing on TPU, 397

updating, 396

risk of tipping, 60

robot

labels, 44

protection class, 55 protection types, 55

symbols, 44

rubber

disposal, 417

S safety

brake testing, 38

ESD, 35

fire extinguishing, 24

moving robots, 29

release robot axes, 25

signal lamp, 87

signals, 42 signals in manual, 42 symbols, 42

symbols on robot, 44

test run, 30

working range, 31

safety equipment

mechanical stop, 99





position switches, 107

signal lamp, 170

safety fence, 22

safety risk

electric parts, 33

hot parts, 36

hydraulic system, 37

installation, 27

oil change, 40

operational disturbance, 27

pneumatic system, 37

service work, 27

voltage, 33

safety signals

in manual, 42

safety standards, 428

safety zones, 22

scales on robot, 394

schedule for maintenance, 127

screw joints, 431

securing

base plate, 73

securing, lower arm, 292

securing, robot, 78

securing, upper arm, 333

securing the robot to foundation, attachment screws, 78

signal lamp, 87

signals

safety, 42

SMB

replacing, 296

SMB battery

extension of lifetime, 192, 296 replacing, 192, 296

special tools, 436

speed

adjusting, 124

stability, 60

standards, 428

ANSI, 429

CAN, 429

EN, 428

EN IEC, 428

EN ISO, 428

start of robot in cold environments, 124

steel

disposal, 417

storage conditions, 55

symbols

safety, 42

synchronization position, 396

sync marks, 394

system integrator requirements, 21

T temperatures


testing

brakes, 38

three-position enabling device, 32

tightening torque


tools

Axis Calibration, 438

447


Index

calibration equipment, Levelmeter, 438

Calibration Pendulum, 438

for service, 436

oil exchange equipment, 439

torques on foundation, 53

TPU

jogging to calibration position, 415



troubleshooting

oil spills, 199

turning disk replacement, 254

turning radius, 59

type A motors, 423 type B motors, 423

type of motion, 59

U


upper arm

dimensions, 83

replacement, 264

V

validity and responsibility, 21

velocity

adjusting, 124

verifying calibration, 413

W

weight, 53

balancing device, 309, 311

base plate, 72, 77

gearbox, 371, 373, 380–381

lower arm, 279–280

motor, 323, 334–335

robot, 65–66, 69, 359, 361, 363, 366, 434

upper arm, 269–270

wrist unit, 261

working range, 56

restricting axis 1, 99



wrist unit, replacement, 258

Z zero position

checking, 414

448




ABB AB, Robotics

Robotics and Motion

S-721 68 VÄSTERÅS, Sweden

Telephone +46 (0) 21 344 400

ABB AS, Robotics


Nordlysvegen 7, N-4340 BRYNE, Norway

Box 265, N-4349 BRYNE, Norway

Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion

No. 4528 Kangxin Highway

PuDong District

SHANGHAI 201319, China

Telephone: +86 21 6105 6666

ABB Inc.


1250 Brown Road

Auburn Hills, MI 48326

USA

Telephone: +1 248 391 9000 abb.com/robotics



ABB IRB 6650S-90/3.9, IRC5 Compact, M2000, M2000A Product Manual

Product manual

IRB 6650S

Table of contents

Overview of this manual

Product documentation, M2000/M2000A

Product documentation, IRC5

How to read the product manual

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Robot description

8 Spare part lists

9 Reference information

10 Circuit diagram

Index

Related manuals

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ABB

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IRB 6660 - 130/3.1

ABB

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ABB

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ABB

IRB 2400/10

ABB

Accessories

ABB

IRB 6650S - 200/3.0

ABB

IRB 4400/60

ABB

MTD 500

ABB

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Table of contents