ABB IRB 6640 Foundry Prime Product Manual

ROBOTICS

Product manual

IRB 6640 Foundry Prime

Trace back information:

Workspace R18-1 version a9

Checked in 2018-03-22

Skribenta version 5.2.025

Product manual

IRB 6640 Foundry Prime - 235/2.55

IRB 6640 Foundry Prime - 185/2.8

IRC5

Document ID: 3HAC040586-001

Revision: N

© Copyright 2011-2018 ABB. All rights reserved.

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

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

Important information about robots with protection type Foundry Prime ......................................

9

14

16

17

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

19

31

32

34

35

26

28

29

30

23

24

25

26

19

19

22

23

36

37

38

39

41

41

43

2 Installation and commissioning 49

2.1

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

2.2

Installation and operational requirements for Foundry Prime robots ............................

2.3

Design 1 and Design 2 of IRB 6640 .......................................................................

2.4

Robot transportation precautions .........................................................................

2.5

Securing the robot with a transport support ...........................................................

2.6

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

2.6.1

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

2.6.2

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

2.6.3

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

2.7

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

2.7.1

Lifting the robot with fork lift accessory .......................................................

2.7.1.1 Fitting the fork lift accessory ..........................................................

2.7.1.2 Lifting the robot with fork lift truck ...................................................

2.7.2

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

2.7.3

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

2.7.4

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

2.7.5

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

2.7.6

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

2.7.7

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

2.7.8

Surface inspection before start-up - Foundry Prime .......................................

2.7.9

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

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

2.7.11 Installing the over pressure limiter unit ........................................................

2.7.11.1 Installing the over pressure limiter on wall ........................................

2.7.11.2 Installing the over pressure limiter unit on robot base .........................

73

76

78

80

69

70

70

70

60

62

62

66

49

50

54

56

96

97

98

99

102

81

86

89

95

Product manual - IRB 6640 Foundry Prime

3HAC040586-001 Revision: N


5


2.8

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

2.8.1

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

2.8.2

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

2.8.3


2.8.4


2.9

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

2.9.1

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

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

107

107

108

110

112

115

115

117

3 Maintenance 119

3.1

Introduction for Foundry Prime robots ...................................................................

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

3.3.2


3.3.3


3.3.4


3.3.5


3.3.6


3.3.7

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

3.3.8

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

3.3.9

Inspection of air hoses (Foundry Prime) ......................................................

3.3.10 Inspection of surface treatment (Foundry Prime) ...........................................

3.3.11 Inspecting the information labels ................................................................

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

3.3.13 Inspecting the additional mechanical stops .................................................

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

3.3.15 Inspecting the signal lamp (option) .............................................................

3.4

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

Analysis activities ..............................................................................................

3.5.1

Analyzing the water content in gearbox oil ...................................................

3.6

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

3.6.1

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

3.6.2

Rust preventive measures, bearing axis 1 (Foundry Prime) .............................

3.6.3

Rust preventive measures, sealing axis 4 (Foundry Prime) ..............................

3.6.4

Rust preventive measures, support bearing in wrist (Foundry Prime) ................

3.6.5

Apply Mercasol on output shaft axis 2 .........................................................

3.6.6

Apply Mercasol on output shaft axis 3 ........................................................

3.7

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

3.7.1

Cleaning the IRB 6640 Foundry Prime .........................................................

173

176

179

182

185

188

193

193

157

159

161

164

166

168

168

170

194

194

198

201

204

206

208

210

210

131

134

136

139

144

150

155

156

119

121

121

122

125

127

127

129

4 Repair 213

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

213

214

214

215

217

219

6 Product manual - IRB 6640 Foundry Prime




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 cabling, axis 5 motor ..........................................................

4.3.3

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

4.3.4

Replacement of air nipple and hose (Foundry Prime) .....................................

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 support shaft with bearing axis 5 ..........................................

4.4.4

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

4.4.5

Replacement of complete 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 (design 1) ........................................

4.5.4.2 Replacing balancing device (design 2) .............................................

4.5.4.3 Unloading the balancing device using distance tool ...........................

4.5.4.4 Restoring the balancing device using distance tool ............................

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

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

4.6

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

4.6.1

Replacing motor axis 1 .............................................................................

4.6.2


4.6.3


4.6.4


4.6.5


4.6.6


4.7

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

4.7.1

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

4.7.2


4.7.3


4.7.4


339

339

346

354

362

370

379

387

297

302

302

311

327

331

333

336

387

405

419

431

259

263

269

273

281

287

287

293

221

222

222

237

240

252

259

5 Calibration information 439

5.1

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

5.2

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

5.3

Synchronization marks and synchronization position for axes ...................................

5.4

Calibration movement directions for all axes ..........................................................

5.5

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

5.6

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

439

440

442

443

444

447

6 Decommissioning 449

6.1

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

6.2

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

6.3

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

6.4

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

449

450

452

453

7 Reference information 457

7.1

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

7.2

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

7.3

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

7.4

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

7.5

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

7.6

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

7.7

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

457

458

460

461

464

465

466




7


7.8

Dismounting and mounting tool 3HAC028920-001 ...................................................

7.9

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

469

485

8 Spare parts 487

8.1

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

487

9 Circuit diagrams 489

9.1

Circuit diagrams ................................................................................................

489

Index 491




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 robot described in this manual has the protection type Foundry Prime .

Usage

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

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 and calibration.

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

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

Organization of chapters

The manual is organized in the following chapters:

Chapter Contents

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

Installation and commissioning

Required information about lifting and installation of the robot.

Maintenance

Repair

Calibration information

Decommissioning

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

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

Procedures that do not require specific calibration equipment.

General information about calibration.

Environmental information about the robot and its components.

Continues on next page





Continued

Chapter

Reference information

Spare part / part list

Exploded views

Circuit diagram

Contents

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 exploded views.

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

Reference to the circuit diagram for the robot..

References

Reference

Product manual - IRB 6640

Product manual, spare parts - IRB 6640

Product specification - IRB 6640

Circuit diagram - IRB 6640

Product manual - DressPack/SpotPack IRB 6640

Operating manual - General safety information i

Product manual - IRC5

IRC5 with main computer DSQC 639.

Product manual - IRC5

IRC5 with main computer DSQC1000.

Document ID

3HAC026876-001

3HAC038330-001

3HAC028284-001

3HAC025744-001

3HAC028638-001

3HAC031045-001

3HAC021313-001

3HAC047136-001

Operating manual - IRC5 with FlexPendant

Operating manual - Calibration Pendulum

Operating manual - Service Information System

3HAC050941-001

3HAC16578-1

3HAC050944-001

Application manual - Additional axes and stand alone controller 3HAC051016-001

Technical reference manual - Lubrication in gearboxes

Technical reference manual - System parameters

Application manual - Electronic Position Switches

Application manual - CalibWare Field 5.0

3HAC042927-001

3HAC050948-001

3HAC050996-001

3HAC030421-001 i

List of approved cleaners and detergents for Foundry Prime robots

Contact ABB local sales organization

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

Revisions

-

Revision

A

Description

First edition

This revision includes the following updates:

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

How to read the product manual on page 16

.

• Robot designations are adjusted in sub-headings in section

Robot transportation precautions on page 56 .






Continued

Revision

B

C

Description

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

Screw joints on page 461 .

• Added

Safety risks during handling of batteries on page 38 .

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

Securing the base plate on page 81

.

• Changed name definition of rust preventive agent from being Mercasol

3106 to be only Mercasol, throughout the manual.

• Reference to Hilti standard added to the foundation recommendation for the base plate and class designation for foundation is changed to european standard C25/C30 (previously Swedish standard K25/K30), see

Securing the base plate on page 81 .

• The section for replacement of wrist unit is completed with gaskets, see

Replacement of complete wrist unit on page 263 .

• 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 168 .

• Corrected dimension data and changed article number for attachment screw, see

Replacing gearbox axis 3 on page 419 .

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

Inspecting the oil level in axis-6 gearbox on page 139 .

• Changed the length of guide pins used to guide the complete arm system when refitting it, see the list of required equipment in

Replacement of complete arm system on page 240 . Also added an alternate

method of lifting the arm system and made some other minor changes to the procedure.

• Changed the length of guide pins and changed pictures of the gearbox, see

Replacing gearbox axis 1 on page 387

.

• Added guide pins and added an alternate method of lifting the arm system, see


• The interval for inspecting the balancing device is changed, see

Maintenance schedule on page 122

.


• Removed row with axis-1 sealing from maintenance schedule, see

Maintenance schedule on page 122

.

• Added a recommendation to analyze the water content in the gearbox oil in

Maintenance schedule on page 122 , and added the instruction

Analyzing the water content in gearbox oil on page 193

as a separate section that is valid for all axes.

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

• Updated the list of approved detergents, see

Approved cleaners and detergents on page 212

.


• Minor corrections in section

Performing a leak-down test on page 214 .

• Corrected part numbers in section


.

• The list of approved cleaners and detergents is updated more frequently than the manual is updated, therefore the information is removed from the manual and instead referenced. See

Approved cleaners and detergents on page 212 .

• Corrected the article number for grease and corrected figures of the gearbox in the procedures, section


.

• Changed article number 3HAA1001-294 to 3HAC042534-001 throughout manual.






Continued

H

J

K

Revision

D

E

F

G

L

M

Description


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

Scrapping of robot on page 452

.


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

Securing the base plate on page 81

.

• Minor corrections.


• Changed spare part number for axis-6 motor gasket.

• The instructions for the fork lift accessory is split into two sections.

• The inspection of oil level in gearboxes is removed from the maintenance schedule and moved to the cleaning section.

• The instructions for inspection of oil level in gearboxes are updated, see

Inspection activities on page 127 .

• Illustrations of SMB battery RMU improved.

• Updated section of 'Replacement of air nipple and hose (Foundry prime)', table and figures.


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

• Rust preventive actions for output shaft on axis 2 and 3 added.

• Replacement of suppport shaft with bearing axis 5 added.


• Minor corrections in brake release section.


• Information regarding air flow added.

Published in release R16.2. This revision includes the following updates:

• New activities in maintenance schedule.

• Minor changes

• Corrections due to updates in terminology.

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

• Drying time for Mercasol added.

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

• Reference added from general information to installation regarding pressurized components.

• Text regarding maximum pressure in pressurized components, in warning added.


• 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 information about screw, Loctite, washers, and tightening torque for wrist cover.

• Updated list of applicable standards.

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

• Section

Start of robot in cold environments on page 117

added.

• Updated note about solid-oil bearing.

• Updated information regarding replacement of brake release board.






Continued

Revision

N

Description

• Updated the instruction regarding,

Installing the over pressure limiter on wall on page 99 .

• Updated the information regarding,

Connect air hose to over pressure limiter unit on page 51

.

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


• Added sections in

General procedures on page 214

.

• Safety restructured.

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

• Information about myABB Business Portal added.

• Added Nickel in Environmental information.




13

Product documentation


Categories for user documentation from ABB Robotics

The user documentation from ABB Robotics is divided into a number of categories.

This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.

All documents can be found via myABB Business Portal, www.myportal.abb.com

.

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware is delivered with a Product manual that generally contains:

• Safety information.

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

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

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

• Calibration.

• Decommissioning.

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

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

• Circuit diagrams (or 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.






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.




15

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 19

.

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.




Important information about robots with protection type Foundry Prime

Important information about robots with protection type

Foundry Prime

Introduction

Foundry Prime robots are specially designed to work in harsh environments. Misuse of the robots or poor installation, cleaning, maintenance and repair can be harmful for the functioning of the robot.

Warranty claims

Warranty claims for defect products due to misuse or failure to fulfil operational and maintenance requirements will not be approved.

Pressurized components

Motors, balancing device and the serial measurement board cavity shall be pressurized on Foundry Prime robots during operation and shut down. The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment.

For more information, see

Pressurized components on page 50

.

Cleaning

Special procedures are needed when cleaning the Foundry Prime robot. See section

Cleaning the IRB 6640 Foundry Prime on page 210 .




17

This page is intentionally left blank

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.





19

1 Safety


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 retain work pieces in the event of a power failure or a disturbance to the controller.





1 Safety


Continued

Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.

CAUTION

Ensure that a gripper is prevented from dropping a work piece, if such is used.




21

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.




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.




23

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 78 .

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.




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.




25

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.





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 robot installation.

Allergenic material

See

Environmental information on page 450

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




27

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.




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.




29

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.




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 .




31

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, robot

A danger of low voltage is associated with the robot 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).





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.




33

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.




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.




35

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.




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.




37

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 62

.




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.





39

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.




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 dangers that can arise when doing the work described in the user manuals. Each danger 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 operator/service personnel do not eliminate the danger.

• 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 xx0200000022 xx0100000002

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.

xx0200000024 xx0100000003

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.

xx0200000023





41

1 Safety

1.4.1 Safety signals in the manual

Continued

Symbol Designation

NOTE

Significance

Describes important facts and conditions.

xx0100000004

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

xx0100000098




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 43

.

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





1 Safety


Continued

Symbol xx0900000813

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.





Symbol

1 Safety


Continued

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





45

1 Safety


Continued

Symbol 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





Symbol

1 Safety


Continued

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





47

1 Safety


Continued

Symbol Description

No mechanical stop xx1000001144

Stored energy

Warns that this part contains stored energy.

Used in combination with Do not disassemble symbol.

xx0900000825

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




2 Installation and commissioning

2.1 Introduction


2.1 Introduction

General

This chapter contains assembly instructions and information for installing the IRB

6640 Foundry Prime at the working site.

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

6640 Foundry Prime, 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 19

before performing any installation work.

Note

If the IRB 6640 Foundry Prime is connected to power, always make sure that the robot is connected to protective earth before starting any installation work.

For more information see:





49


2.2 Installation and operational requirements for Foundry Prime robots

2.2 Installation and operational requirements for Foundry Prime robots

Introduction

Robots with protection type Foundry Prime are specially designed to work in harsh environments. To ensure that the protection offers the best reliability, special measures are required during installation and operation. It is required that the environmental and application conditions are fulfilled and that the special maintenance activities and intervals for the Foundry Prime protected robot are followed.

Fluids in the vicinity of the robot

If fluids that can cause rust formation, for example, water etc., are used in the vicinity of the robot it is required to add rust inhibitor to the fluid or take other measures to prevent rust on unpainted joints or other unprotected surfaces of the robot.

Activity to lubricate gearboxes cavities and gears

Run each axis on high speed at least once per hour. This activity will lubricate the gearbox cavities and gears, which reduces the risk for corrosion due to condensation in the gearboxes.

Pressurized components

The motors, the balancing device, and the serial measurement board cavity must be pressurized on Foundry Prime robots during operation and shut down. The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment.

At the installation of the Foundry Prime robot a pressure sensor and pressure relief valve (not included) must be installed in the air supply system to monitor the supply of air pressure in order to secure a correct pressure. See

Pressurizing equipment on page 51

for equipment specifications.

Note

The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independent of Motors On/Off mode, start-up, and shut down periods.

WARNING

Do not to exceed the maximum pressure of 0.3 bar. If the air pressure exceeds the specified, it can lead to damage to the gearbox or brake failure in the motors which may cause the robot arms to fall down, leading to personal injury or physical damage.







Continued

WARNING

If the pressurized air contains oil, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage.

Note

To secure the supply of air pressure, use a pressure sensor.

Air quality for pressurizing of robot

The air must be dry and clean, such as instrument air. The following table describes the air specifications.

Parameter

Dew point

Solid particle size

Oil content

Air flow

Value

<+2°C at 6 bar

<5 microns

<1 ppm (1 mg/m 3 )

>200 L/min

Pressurizing equipment

ABB recommends a safety valve (if not included) set at 0.4 bar, pressure sensor set at 0.2-0.3 bar or regulator set for maximum 0.3 bar to be attached on the pressure side of the air system.

Example of products:

Equipment

Pressure sensor

Pressure regulator

Description

Festo SDE1-series

Festo LRP-series

Connect air hose to over pressure limiter unit

Note

ABB recommends the air pressure to be set at maximum 0.3 bar.





51



Continued xx1700001156

A

B

Connection used by the customer to supply air pressure to the robot.

Air hose between the robot and the OUT 1 connector on the over pressure limiter unit.

Precautionary measures

Note

It is strictly forbidden to expose any part of the robot to direct high pressure water jet! The sealing joints between the moving parts on the wrist must not be exposed to high pressure water.

Rebounding high pressure water jet must be avoided. ABB recommends using a tool design with integrated covers that protect the wrist from direct or indirect high pressure water jet.

Note

Make sure that the special Foundry Prime painting of the robot is not broken during testing, installation, or repair work. Use the touch up kit available for

Foundry Prime (article number 3HAC035355-001) to repair any damages in the paint.







Continued

Sensitive points IRB 6640

Illustration shows points that are particularly sensitive to water spray.

xx0600002792

A

B

C

Axis 5, bearing support side

Axis 5, bearing gear side

Axis 6, mounting flange - gear house

Shut-down periods

During shut-down periods the cleaning cell must be ventilated out (aired out). This reduces the risk that moister is sucked into gearboxes during cooling down. It gives the robot the possibility to dry as the rust inhibition effect normally gets reduced after some time.

Ventilate and air out the cell during and after shut-downs:

• The cell must be ventilated during shut-down until the atmospheric humidity in the cell has reached the same level as the surrounding environment.

• Will avoid that humid air is trapped into gearboxes or other cavities due to raised vacuum when cooling down.

• Will give the robot a chance to dry as most rust preventive components in washing detergents have a decaying effect, i.e. the rust preventive effect is reduced after a time. Please refer to the Product Specification of the washing detergent in question for decaying effect. Washing detergent or water without rust inhibitor can give an accelerated corrosion on some robot components.

• The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independent of Motors On/Off mode, start-up and shut down periods .




53


2.3 Design 1 and Design 2 of IRB 6640

2.3 Design 1 and Design 2 of IRB 6640

Differences in design

There are some differences in the two designs of the robot IRB 6640.

Design 1 has:

• one ear on the lower arm as shown in the figure for design 1.

Design 2 has:

• two ears on the lower arm as shown in the figure for design 2

Design 1 xx0800000401





Design 2


2.3 Design 1 and Design 2 of IRB 6640





55


2.4 Robot transportation precautions

2.4 Robot transportation precautions

General

This section describes ABB approved transportation precautions for ABB robots.

CAUTION

All transportation in or outside the plant, must be carried out according to the method described in this section.

Transportation in any other way can seriously damage the robot. If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim.

Method 1 - recommended method

Transportation according to method 1 is strongly recommended by ABB.

xx0800000030

Always follow these instructions when transporting an ABB robot according to method 1:

• Always remove the tool before transportation of the robot.

• Always place the robot in the ABB recommended transport position, described in section

Risk of tipping/stability on page 69 .

• Always read and follow the instructions in section

Pre-installation procedure on page 62

Method 2 - transportation with a tool mounted to the robot

Transportation according to method 2 is approved by ABB, only if use of method

1 is not possible.







Continued

Always follow these instructions when transporting an ABB robot according to method 2:

• Always read and follow the instructions in section

Securing the robot with a transport support on page 60

• Always place the robot in the ABB recommended transport position for robot with tool, described in sub section

Transport position with a transport support on page 58 .

• Always use the recommended transport support described in sub section

Recommended transport support on page 59 .


C

D

A

B xx0800000037

A

B

C

D

Transport Support

Hexagon socket head cap screw M16x140

Threaded bar M10x200

Nut M10





57



Continued

Transport position with a transport support

All transportation of the robot with tool must follow these instructions.

IRB 6640 Foundry Prime xx0800000040







Continued

Recommended transport support

Always use the recommended transport support when transporting a robot with tool.

IRB 6640 Foundry Prime xx0800000039




59


2.5 Securing the robot with a transport support

2.5 Securing the robot with a transport support

General

This section describes how to fit the transport support to the robot in order to secure the robot for transportation. The transport support is required if the robot must be transported with mounted tools.

DANGER

Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary.

Fitting the transport support

Illustration for fitting the transport support

B

A xx0800000062






2.5 Securing the robot with a transport support

Continued

Fitting the transport support

1

Action

Fit the transport support’s lower end to the robot using the recommended screw joint,

(A) in figure.

Note

Do not tighten the screw.

See attachment point for the specific robot in the section


2 Jog the robot into a position as near above as possible to the recommended transport position for the specific robot, as specified in section


CAUTION

Do not try to jog the robot to the exact position (max distance 1mm).

3 Use the brake release for axis 3 to reach the final resting position on the transport support, see the section


See attachment point for the specific robot in the section

Transport position with a transport support on page 58

4 Tighten all the attachment screws, (A) and

(B), in the figure with the brake release for axis 3 still activated starting with the lower attachment screw.

CAUTION

Do not attempt to tighten any attachment screws without first releasing the brakes.

This can seriously damage the robot.

5 Use the brake release for axis 5 and 6 to reach the final resting position for the tool, see the section

Manually releasing the brakes on page 78




61


2.6.1 Pre-installation procedure

2.6 Unpacking

2.6.1 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 62

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

Storage conditions, robot on page 64

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

Operating conditions, robot on page 65

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

•

Loads on foundation, robot on page 63

•

Protection classes, robot on page 65

•

Requirements, foundation on page 64

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

Risk of tipping/stability on page 69

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

On-site installation on page 70

Install required equipment, if any.

•

Signal lamp (option) on page 97

Weight, robot

The table shows the weight of the robot.

Robot model


Weight

1,340 kg (IRB6640), 1,405 kg (IRB6640ID)







Continued

Note

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

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!

WARNING

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

Floor mounted

Force

Force xy

Endurance load (in operation)

± 8.5 kN




Max. load (emergency stop)

± 20.4 kN


63



Continued

Force

Force z

Torque xy

Torque z

Endurance load (in operation)

15.0 ± 9.0 kN

± 20.1 kNm

± 5.1 kNm

Max. load (emergency stop)

15.0 ± 20.0 kN

± 45.2 kNm

± 10.6 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.

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

100% at constant temperature

(gaseous only)







Continued

Operating conditions, robot

The table shows the allowed operating conditions for the robot:

Parameter




Value

+5° C

+50° C

100% at constant temperature

(gaseous only)

Protection classes, robot

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

Protection type

Manipulator, protection type Foundry Prime

Protection class

IP 67




65


2.6.2 Working range and type of motion

2.6.2 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 6640 - 180/2.55, 235/2.55, 205/2.75, 185/2.8, 130/3.2 & IRB 6640ID - 200/2.55, 170/2.75

The illustration below shows the unrestricted working range. Measurements for the different robot variants, are shown as A to F, in the illustration below.

xx0600003396

Robot variant

IRB 6640-2.55

IRB 6640-2.75

IRB 6640-2.8

IRB 6640-3.2

A

3015 mm

3219 mm

3261 mm

3665 mm

IRB 6640ID-2.55

IRB 6640ID-2.75

3015 mm

3219 mm

B

286 mm

268 mm

533 mm

713 mm

286 mm

268 mm

C

2550 mm

2755 mm

2800 mm

3200 mm

2550 mm

2755 mm

D

903 mm

961 mm

1004 mm

1067 mm

903 mm

961 mm

E

1119 mm

1252 mm

1324 mm

1604 mm

1549 mm

1682 mm

F

1814 mm

1999 mm

2061 mm

2445 mm

1814 mm

1999 mm







Continued

Turning radius

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

xx0600003399

IRB 6640 - 2.55

IRB 6640 - 2.75

IRB 6640 - 2.8

IRB 6640 - 3.2

IRB 6640ID - 2.55

IRB 6640ID - 2.75

2550 mm

2755 mm

2800 mm

3200 mm

2550 mm

2755 mm

Type of motion

2

3

4

Axis

1

5

Type of motion

Rotation motion

Arm motion

Arm motion

Wrist motion

Bend motion

Range of movement

+170° to -170°

Note

Movement range can be set to:

+220º to -220º (option 561-1)

+85º to -65º

+70º to -180º

+300° to -300° IRB 6640ID: the range of movement is the combined value for axis 4 and 6 together.

IRB 6640:

+120° to -120°

IRB 6640ID:

+100º to -100º







Continued

Axis

6

Type of motion

Turn motion

Range of movement

IRB 6640:

+360º to -360º (default),

± 96 revolutions

IRB 6640ID:

+300° to -300°

±300º max

1)

Note

1)

The minimum combination of axes 4 and 6.

Note

There are limitations of the range of movement with a DressPack/SpotPack application fitted to the robot! See product manual SpotPack/DressPack IRB

6640 chapter Installation section DressPack cable package . Art. no. can be found in section

Working range and type of motion on page 66 .





2.6.3 Risk of tipping/stability

2.6.3 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.

10° Ax3

Ax2

45°

Ax5

80°

Z

X

Y xx0600003400

WARNING

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




69


2.7.1.1 Fitting the fork lift accessory

2.7 On-site installation

2.7.1 Lifting the robot with fork lift accessory

2.7.1.1 Fitting the fork lift accessory

Required equipment

The following equipment is required when lifting a robot with the fork lift accessory:

Equipment

Fork lift pocket set

Fork lift truck -

Art. no.

3HAC025040-003

Note

The fork lift accessory set contains:

• fork lift pocket

3HAC025528-001, with CE-

Marking fitted (4 pcs)

• attachment screws

M20x60 Steel 8.8-A3F (8 pcs)

• Drawing Fork lift accessory set

• manual Directions for use - Fork lift accessory for

IRB 6620, 6640, 460

The operator must be fully trained and authorized to operate a fork lift truck.

Preparations before fitting the fork lift pockets

1

Action Note

Remove any tools fitted on the axis-6 turning disk.

Note

DressPack, if used, can stay fitted as long as the tool fitted on the turning disk is removed.

No tool is permitted to be fitted on the robot when lifting the robot with the fork lift accessory!

2 Jog the robot to its shipping position. See figures for the different IRB models.

10° Ax3

Note

The figures shows the shipping position of an undressed robot. If the robot is dressed, this must be taken into consideration when the robot is being lifted.

Z

Ax2

45°

Ax5

80°

X xx0600003400

Y







Continued

Action

3

DANGER

Turn off all:

• electric power supply

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

Note

Attachment points on the robot

The fork lift accessory is fitted on the robot as shown in the figure.

xx0600002910

A

B

Fork lift pocket

Attachment screw M20x60 quality 8.8 (2 pcs x4)





71



Continued

Fitting the fork lift accessory set

1

Action Note

Fit the four fork lift pockets on the base of the robot with its attachment screws.

Tightening torque: 300 Nm

Note

Before fitting any attachment screws, make sure they are not damaged in any way. Replace damaged screws.

2 Verify that all four fork lift pockets are properly secured before lifting.

xx0600002930

A Fork lift pocket (4 pcs)

B Attachment screw M20x60 quality 8.8 (2 pcs x4)





2.7.1.2 Lifting the robot with fork lift truck

2.7.1.2 Lifting the robot with fork lift truck

General

The robot may be moved using a fork lift truck, provided that a complete fork lift accessory set, aimed for the robot, is used.

This section describes how to lift the robot with a fork lift truck.


Equipment

Fork lift accessory

Fork lift truck

Art. no.

3HAC025040-003

Note

Lifting the robot with fork lift truck

1

Action

Make sure that the robot is in shipping position!

Note

Note

No load is permitted on the robot!

2

3

DANGER

Make sure that all supplies for electrical power and hydraulic pressure are turned off.

Verify that all four fork lift pockets are properly secured before lifting.





73



Continued

4

Action

Insert fork lift forks into the pockets.

CAUTION

Lifting the robot with fork lift shall only be done with all four fork lift pockets fitted!

If lifting with fewer than four fork lift pockets fitted, there is a risk of accidents!

Note

IRB 6620 xx0600002911

IRB 6640

0°

1 Ax3

Ax2

45°

A x5

80° xx0600003401

IRB 460 xx1000001159







Continued

5

Action

Remove the attachment bolts securing the robot to the foundation.

Note

6

7

8

CAUTION

.

The IRB 6640 Foundry Prime robot weighs

1,340 kg (IRB6640), 1,405 kg (IRB6640ID)

All lifting accessories used must be sized accordingly!

Carefully lift the robot.

WARNING

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

Move the robot slowly to its new position.

Note

Move the robot with low speed!

Secure the robot to the foundation 9

DANGER

Do not power the robot up until it is secured properly to the foundation.

10 Remove the fork lift accessories.




75


2.7.2 Lifting robot with roundslings

2.7.2 Lifting robot with roundslings

General

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

Sling specification

Sling type

Roundsling, robot

Roundsling, upper arm

Qty

4 pcs

1 pc

Lifting capacity

2 000 kg

2 000 kg

Length / Note

2.5 m

Note!

Do not stretch!

2 m

Secures against rotation.

Lifting with roundslings

1

2

Action

Position robot in a secure transport position.

Attach roundslings to robot according to figure

Attachment points on page 77 .

Note

Note

For Cleanroom robots it is important to apply the roundslings:

• between robot harness and lower arm

• behind the side bracket, balancing cylinder.

3

CAUTION Note

The IRB 6640 Foundry Prime robot weighs

1,340 kg (IRB6640), 1,405 kg (IRB6640ID) .


If the robot is equipped with fork lift pockets an extra weight of 90 kg must be added to the robot weight!

4

WARNING

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






2.7.2 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.

IRB 6640 standard.

xx0600003455

-

A

B

C

D

Lifting instruction 3HAC027647-001

Roundsling robot, 2.5 m (4 pcs) Capacity: 2.000 kg.

Roundsling upper arm, 2 m.

Note!

Make a loop around the upper arm and wrap the roundsling twice around the upper arm!

Do not stretch!

Lifting eye M20 (4 pcs).

Note!

Fit lifting eyes in the rear holes.

Holes for lifting eyes in the robotbase. (Rear holes)




77


2.7.3 Manually releasing the brakes

2.7.3 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.

xx0600003402

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 79

.

Buttons are shown in figure

Location of brake release unit on page 78 .

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.






2.7.3 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




79


2.7.4 Lifting the base plate

2.7.4 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 80

.

CAUTION

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





2.7.5 Securing the base plate

2.7.5 Securing the base plate

Base plate, dimensions

D G

F

B

B

H

2x R525

598,31

560,85

487,01

(Ø 800)

12x M24

Ø1 A

455

243,5

A

A

E

0

73,84

111,30

C C

2x 50x45º

857,3

1020

4x48

0.3

Common Zone

E, F, G, H

A

A-A

Ø 45P7

Ø1.5

3x45º

13

(2)

(48)

B-B

(4x)

6,3

(2)

1,6

3x45º

(2)

13

3x R1

45

K

7 c

47

0

+0,5

52,5º

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)





81




A Four holes for alternative clamping, 4x Ø18







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)





83



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

3HAC12937-9 Includes

• guide sleeves, 3HAC12937-3

• levelling screws, 9ADA120-79

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

Content is defined in section

Standard tools on page 465 .

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 83 .

Detailed in section

Lifting the base plate on page 80 .

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 83 .

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.




85


2.7.6 Orienting and securing the robot

2.7.6 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.

xx0600002933

C

D

A

B

Robot attachment bolts and washers, 8 pcs (M24 x 100)

Orienting grooves in the robot base and in the base plate

Levelling screws.

Note!

Remove before the robot base is fitted!

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 100

Quality 8.8

Thickness: 4 mm

Outer diameter: 44 mm

Inner diameter: 25 mm

725 Nm







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 roundslings on page 76 .

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 84 .

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 86 .

Shown in figure

Illustration, robot fitted to base plate on page 86 .

Note

Lightly lubricate screws before assembly!

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





87



Continued

Hole configuration, base

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

xx0600003403

Cross section, guide sleeve hole

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

88 xx0600003404





2.7.7 Fitting equipment on robot

2.7.7 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.

Illustration, fitting of extra equipment on lower arm

The illustrations 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!

Note!

Extra equipment may not be mounted on the lower arm of IRB 6640ID!

Note!

Extra equipment may not be fitted on the lower arm of Cleanroom robots!

4 x M12

150

75 xx0600003405

627

320

380





89



Continued

Robot variant

IRB 6640 - 2.55

IRB 6640 - 2.75

IRB 6640 - 2.8

IRB 6640 - 3.2

IRB 6640ID - 2.55

IRB 6640ID - 2.75

A

2240 mm

2445 mm

2240 mm

2445 mm

2240 mm

2445 mm

B

520 mm

725 mm

520 mm

725 mm

520 mm

725 mm

C

1075 mm

1280 mm

1075 mm

1280 mm

1075 mm

1280 mm xx0600003406

Robot variant

IRB 6640 - 2.55

IRB 6640 - 2.75

IRB 6640 - 2.8

IRB 6640 - 3.2

IRB 6640ID - 2.55

IRB 6640ID - 2.75

A

400 mm

500 mm

400 mm

500 mm

400 mm

500 mm

B

13 mm

13 mm

13 mm

13 mm

13 mm

13 mm

C

40 mm

30 mm

40 mm

30 mm

40 mm

30 mm







Continued

Illustration, fitting of extra equipment on upper arm

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

Note!

Extra equipment may not be fitted on the upper arm of IRB 6640ID and

Cleanroom robots!

xx0600003414

Robot variant

IRB 6640 - 2.55

IRB 6640 - 2.75

IRB 6640 - 2.8

IRB 6640 - 3.2

IRB 6640ID

IRB 6640ID

A

1142 mm

1142 mm

1392 mm

1592 mm

1142 mm

1142 mm

B

200 mm

200 mm

200 mm

200 mm

290 mm

290 mm xx1000000158





91



Continued

Illustration, fitting of extra equipment on frame

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

xx0600003416







Continued

Illustration, fitting on turning disc

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

There are different versions of the turning disc, as shown in the illustrations below.

xx0200000397

Turning disk type 1





93




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.





2.7.8 Surface inspection before start-up - Foundry Prime

2.7.8 Surface inspection before start-up - Foundry Prime

Foundry Prime coating

Make sure that the special Foundry Prime painting of the robot arm surfaces is not broken or there have been any other damages during testing and installation.

Even a small collision during installation can destroy the preventive coating and the corrosion barrier is broken. Use the Touch up kit available for Foundry Prime,

3HAC035355-001, to repair damages to paint surfaces.

Pre-installation procedure/ Operation conditions, robot

Parameter




Value

+5° C

+50° C

100% at constant temperature (gaseous only)

Protect attachment bolts and washers at the base

Protect the attachment bolts and washers (M24x100) at the base from physical obstructions and splashes with appropriate shield.




95


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

2.7.9 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.

• 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.





2.7.10 Signal lamp (option)

2.7.10 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.




97


2.7.11 Installing the over pressure limiter unit

2.7.11 Installing the over pressure limiter unit

General

ABB recommends the over pressure unit to be placed away from the robot, preferably attached on a nearby located wall to minimize exposure to water and detergent. Direct contact to water or detergent shall be avoided as it will decrease the lifetime of the over pressure limiter unit.

For more information, see the recommended solution

Installing the over pressure limiter on wall on page 99

or the alternative solution

Installing the over pressure limiter unit on robot base on page 102

.

Note

An extra warning label is supplied with the robot and must be applied on the robot base if the over pressure unit is installed on the robot base.






2.7.11.1 Installing the over pressure limiter on wall

2.7.11.1 Installing the over pressure limiter on wall

General

ABB recommends the over pressure unit to be placed away from the robot, preferably attached on a nearby located wall to minimize exposure to water and detergent. Direct contact to water or detergent shall be avoided as it will decrease the lifetime of the over pressure limiter unit.

Location of the over pressure limiter unit

Required equipment xx1700001149

Equipment, etc.

Over pressure unit

Standard toolkit -


For spare part number see:

•

Spare parts on page 487


Standard tools on page 465

.

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling parts. See

Cut the paint or surface on the robot before replacing parts on page 219

.







Continued

Installing the over pressure limiter unit

Action

1

DANGER

Turn off all:


• hydraulic pressure supply

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

2 Attach the over pressure limiter unit to the wall.

Note xx1700001151

3 Connect the air hose to unit.

4 Connect the air hose from the unit to the connector plug on the robot base.

xx1700001150

5 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 29

.

xx1700001906







Continued

Removing the over pressure limiter unit

Action

1

DANGER

Turn off all:




2 Disconnect the air hose from the unit.

Note

3 Disconnect the air hose from the the robot base.

xx1700001150

4 Remove the unit from the wall.

xx1700001906 xx1700001151




101


2.7.11.2 Installing the over pressure limiter unit on robot base

2.7.11.2 Installing the over pressure limiter unit on robot base

General

ABB recommends the over pressure unit to be placed away from the robot, preferably attached on a nearby located wall to minimize exposure to water and detergent. Direct contact to water or detergent shall be avoided as it will decrease the lifetime of the over pressure limiter unit. For more information see

Installing the over pressure limiter on wall on page 99 .

Note

An extra warning label is supplied with the robot and must be applied on the robot base if the over pressure unit is installed on the robot base.

Location of the over pressure limiter unit


Equipment, etc.

Over pressure unit


-

For spare part number see:

•




.

Standard toolkit







Continued

Equipment, etc.

Plastic mallet -


If the robot is equipped with a removable plate on the robot base.

CAUTION



.

Installing the over pressure limiter unit

Action

1

DANGER

2

3

Turn off all:




Fit the extra warning label onto the robot and near the over pressure limiter unit clearly visible for the operator.

Remove the top cover from the robot base.

Note

4 Disconnect the air hose from the plug on the connector plate.

Note

If the robot is equipped with a perforated plate and not a connector plate, then remove the perforated plate by hitting it with a plastic mallet before attaching the over pressure limiter unit.

xx1700001822 xx1700001823





103



Continued

5

Action

Remove the connector plate from the robot base.

Note

6 Attach the over pressure limiter unit to the robot base.

xx1700001824 xx1700001901

7 Connect the air hose to the unit.

xx1700001902

8 Refit the top cover.

xx1700001903







Continued

9

Action

Connect the air hose to the unit.

Note xx1700001904

10 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section


.

Removing the over pressure limiter unit

Action

1

DANGER

Turn off all:




2 Disconnect the air hose from unit.

Note

3 Remove the top cover from the robot base.

xx1700001904 xx1700001905





105



Continued

4

Action

Disconnect the air hose from the unit.

Note

5 Remove the unit from the robot base.

xx1700001902 xx1700001901





2.8.1 Axes with restricted working range

2.8 Restricting the working range

2.8.1 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.



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.




107


2.8.2 Mechanically restricting the working range of axis 1

2.8.2 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.

xx0600002938

C

D

A

B

Movable mechanical stop

Attachment screw plus washer, M12 x 40 quality 12.9 (2 pcs)

Fixed mechanical stop

Mechanical stop pin axis 1







Continued


Equipment, etc.

Movable mechanical stop set, axis 1

(+15°/-7.5°)

Article number

3HAC025204-003

Note

Includes:

• one stop (+15°/ -7.5°),

3HAC025366-001

• one stop (+7.5°/ -15°),

3HAC025367-001

• attachment screws and washers

• document for movable mech.stop, 3HAC025204-

002

Standard toolkit


-

-

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:

• electric power supply to the robot

• hydraulic pressure supply to the robot

Before entering the robot working area.

2

3

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

Mechanical stops, axis 1 on page 108

.

Tightening torque: 120 Nm.

Adjust the software working range limitations

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

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.




109




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.

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

xx1000000163

A

B

C

Additional stops, axis 2

Fixed stop, axis 2

Attachment screw + washer M16x50 quality 12.9


Equipment, etc.

Art. no.

Mechanical stop set, axis 2 3HAC13787-1

Standard toolkit -


-

Note

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



.

Art. no. is specified in section



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:










Continued

2

3

Action Note

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


Shown in the figure


.

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


4

WARNING






111




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


Attachment screw M16x60 quality 12.9








A

B

Mechanical stop pin, axis 3

Attachment screw and washer


Equipment, etc.

Mechanical stop set, axis 3

Art. no.

3HAC13128-1

Standard toolkit


-

-

Note

Includes:

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

• attachment screws.



.







113



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


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







2.9.1 Robot cabling and connection points

2.9 Electrical connections

2.9.1 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 115 .

Customer cables (option) 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) , see document number in


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 Connection point, cabinet

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

XS1

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

XS2

Connection point, robot

R1.MP

R1.SMB

Robot cable, power

Cable

Robot cable, power: 7 m




Art. no.

3HAC026787-001

3HAC026787-002

3HAC026787-003

3HAC026787-004





115


2.9.1 Robot cabling and connection points

Continued

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

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.

116 xx1500001603





2.10 Start of robot in cold environments

2.10 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.




117


3 Maintenance

3.1 Introduction for Foundry Prime robots

3 Maintenance

3.1 Introduction for Foundry Prime robots

Introduction

The Foundry Prime robots are designed for installation and operation in very hard environments. Misuse of the robots, as well as poor installation, cleaning, maintenance, and repair can be harmful for the functioning of the robot.

To eliminate these risks appropriate equipment and procedures are required when installing, cleaning, maintaining, and repairing ABB Foundry Prime robots.

An extended maintenance program including service activities and schedule is required.

Cleaning and maintenance of robots with Foundry Prime protection shall be performed by trained personnel.

Specific maintenance activities and intervals for Foundry Prime

The Foundry Prime robots have specific maintenance activities and intervals compared to standard robots:

• More comprehensive

• More frequent

• Sample activities for check of lubrication

• Conditional - for example, water content in gearbox control/decide replacement intervals

Preventive measures every 6 months secure the uptime of the robot:

• Inspection of oil level in gearboxes

• Surface treatment

• Cable harness

• Balancing device

Activity to lubricate gearboxes cavities and gears

Run each axis on high speed at least one occasion per hour. This activity will lubricate the gearbox cavities and gears, which reduce the risk for corrosion due to condensation in gearboxes.

Non-predictable situations

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

Note

Repair damages on painted surfaces as soon as possible. Use the touch-up kit

3HAC035355-001 for Foundry Prime protection.





3 Maintenance

3.1 Introduction for Foundry Prime robots

Continued

Warranty claims

Warranty claims for defect products due to misuse or failure to fulfil operational and maintenance requirements will not be approved.




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 6640 Foundry Prime:

• 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 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.




121

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 table below.

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 125

Note

For best reliability, it is of highest importance that the special maintenance instructions for the Foundry Prime robot are followed and documented.

Activities and intervals, Foundry Prime

The following table specifies the required maintenance activities and intervals for robots with protection type Foundry Prime.

Maintenance activity

Equipment

Inspection Surface treatment

Inspection

Inspection

Replacement

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Analysis

Balancing device

Cable harness

(Including rubber blocks and straps)

Cable harness

Air hoses

Inspect for corrosion on support shaft with bearing axis5

Information labels

Dampers

Mechanical stop, axis 1

Oil level in gearbox axis 1-6

Oil gearbox axis 1-6

Interval

Every:

• 6 months i

Every:

• 2 months

Every:

• 6 months

If required ii

If required

ii

Every:

• 6 months

Every:

• 6 months

If corroded: Replace support shaft with bearing. See

Replacement of support shaft with bearing axis 5 on page 269 .

Every:

• 12 months

Every:

• 12 months

Every:

• 12 months

Every:

• 2 months at start up

• 6 months

Every:

• 6 months





3 Maintenance


Continued

Maintenance activity

Equipment

Changing iii

Oil in axis-1 gearbox

Changing

Changing

Changing

Changing

Changing

Changing

Changing

Changing

Overhaul

Overhaul

iii iii iii iii iii

Replacement

Replacement

Lubrication

Lubrication

Rust preventing

Rust preventing

Rust preventing

Rust preventing

Rust preventing

Interval



Every:

• 6 months

Every:

• 6 months

Every:

• 6 months




Support shaft with bearing axis 5

Every:

• 6 months

Every:

• 6 months

Every:

• 6 months iv

Every:

• 12 months

Every:

• 12 months

Every:

• 24 months

Balancing device, bearings (Standard bearings, rear and front)

Balancing device, bearings (Solid oil bearings, rear and front)

Battery pack, measurement system of type RMU101 or RMU102 (3-pole battery contact)

36 months or battery low alert v

Battery pack, measurement system with

2-pole battery contact, e.g. DSQC633A

Battery low alert vi

Robot

Axis-6 gearbox

40,000 hours

Balancing device, bearings (Standard bearings, rear and front)

Balancing device, bearings (Solid-oil bearings, rear and front)

Every:

• 24 months

Every:

• 6 months

No re-greasing needed

Apply Mercasol on output shaft Axis-2 gear

Every:

• 6 months

Apply Mercasol on output shaft Axis-3 gear

Every:

• 6 months

Apply Mercasol on support shaft with bearing axis 5

Axis-1 sealing

Axis-4 sealing

Every:

•

Every:

6 months

• 6 months

Every:

• 6 months

Rust preventing Axis-5 sealing Every:

• 6 months i ii iii

Damage to painted surfaces must be repaired as soon as possible to avoid corrosion.

The warranty does not apply to effects or wear caused by environmental factors.

Before changing oil, always check the oil level. Always analyze the water content in the exchanged oil, according to


, to determine the condition of each gearbox.

If the water content in oil is more than 3%, analyze the new oil within 2 months. Repeatedly high water content in oil indicates wear of radial sealing in the gearbox.





3 Maintenance


Continued iv If the robot is working in cleaning cells that are not emptied when the robot is switched off, the oil may be replaced more frequently.

See also


.

v

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.

vi 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.




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.

Note

For expected component life of Foundry Prime robots see

Expected component life - protection type Foundry Prime on page 125 .

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 40,000 hours iv

Gearboxes v

40,000 hours 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

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.

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

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 .

Expected component life - protection type Foundry Prime

The demanding nature of using Foundry Prime robots in a washing application, can shorten the life of the robot’s components compared to that of standard robots in a typical robotic application. See

Expected component life - protection type

Standard on page 125

for standard robots. Depending on the actual washing application, the life of an individual robot can vary or being reduced.

The life of Foundry Prime robots in washing applications will depend on a number of factors. The most important factors are:

• the washing detergent used

• the ambient environment





3 Maintenance

3.2.3 Expected component life

Continued

• installation, maintenance, and repair procedures

• the operation cycle of the robot.




3 Maintenance

3.3.1 Inspecting the oil level in axis-1 gearbox

3.3 Inspection activities

3.3.1 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.

A

B

C xx0600003449

A

B

C

Oil plug, filling

Oil plug, inspection

Oil plug, draining


Equipment

Lubricating oil

Standard toolkit


-

Art. no.

See


Note

Note

Do not mix with other oils!








127

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

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 39

.

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 .

Shown in figure

Location of gearbox on page 127 .

A

Measure the oil level.

Required oil level: 0-10 mm

6 Adjust the oil level, if required.

7 Refit the oil plug.

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 168 .

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

Changing oil, axis-1 gearbox on page 170

.

Tightening torque:24 Nm




3 Maintenance




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

xx0600003451

A

B

C

Oil plug, ventilation

Oil plug, filling and inspection

Oil plug, draining


Equipment, etc.,

Lubricating oil

Standard toolkit


-

Art. no.

Note

See

Type and amount of oil in gearboxes on page 168

.

Note!







Action Note

1

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 39 .





3 Maintenance


Continued

Action Note

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



.


Shown in the figure


A



B

C xx1400002785

A Oil plug hole


C Gearbox oil



Filling of oil is detailed further in the section

Filling, oil on page 174

.





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 442 .

3

DANGER

Turn off all:




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

±10°C.

5

6

Open the oil plug, filling and inspection



.


Shown in the figure


A

B

C xx1400002785

A Oil plug hole


C Gearbox oil





7

Action

Adjust the oil level, if required.


3 Maintenance


Continued

Note



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

Filling, oil on page 178 .





133

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







3 Maintenance


Continued

2

Action

Move the robot to the calibration position.

Note

This is detailed in section

Synchronization marks and synchronization position for axes on page 442

.

3

4

5

6

DANGER

Turn off all:





±10°C.


Open the oil plug, filling and inspection .

Shown in the figure

Location of gearbox on page 134

.

A





B

C xx1400002785

A Oil plug hole


C Gearbox oil




Filling, oil on page 180

.





135

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





3 Maintenance



B

C

-

A

The figure above shows the wrist unit of IRB 6640ID

Wrist unit, axis 5


Oil plugs, draining


Equipment etc.

Lubricating oil

Standard toolkit


-

Art. no.

See


.

Note






Action Note

1

WARNING




2 Move the robot upper arm to a horizontal position.





3 Maintenance


Continued

3

Action

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): 24-36 mm



xx0500002222




Filling, oil, axis 5 on page 183 .





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

A

B

C xx0400001092

Type 2

Axis-6 gearbox


Oil plug, draining





139

3 Maintenance



B

C

-

A

The figure above shows the wrist unit of IRB 6640ID

Axis-6 gearbox

Oil plugs, draining

Oil plug, filling

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 141

.

To inspect oil level for wrist type 2, see

Inspecting the oil level in axis-6 gearbox, wrist type 2 on page 142

.


Equipment

Lubricating oil

Standard toolkit


-

Art. no.

See


Note








3 Maintenance


Continued

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.


Open the oil plug, filling and inspection .

A xx1300000244

6

7

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

Open the oil plug, draining .

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 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°.





3 Maintenance


Continued

9

Action

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 .

Note

C xx1400002786

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.

A

B

A Oil plug hole


C Gearbox oil




.


Filling, oil, axis 6 on page 186

.


11

12

Refit the oil plugs.

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 .

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:








3 Maintenance


Continued

4

Action


±10°C.

Note


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 xx1400002786

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.

A

B

A Oil plug hole


C Gearbox oil


9

10

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 .



.


Filling, oil, axis 6 on page 186 .





143

3 Maintenance

3.3.7 Inspecting the balancing device

3.3.7 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.

xx0600003431

E

F

C

D

A

B

Balancing device

Piston rod (inside balancing device)

Fork / Link ear

Shaft

Retaining ring, bore

Attachments in cradle (rear bearing)





3 Maintenance


Continued


Equipment, etc.

Design 1 :

Maintenance parts, shaft

Spare part no.

3HAC029054-001

Art. no.

Design 2 :


3HAC033411-001

Design 1 :

Maintenance parts, cradle

3HAC029288-001

Design 2 :


3HAC033413-001

Securing screw

Toolkit for maintenance

Standard toolkit

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

Note

For maintenance of balancing device.

Includes:

• bearings, o-rings and seals ( Front bearing ).


Includes:

• bearings, o-rings and seals ( Front bearing ).


Includes:

• bearing, o-ring and sealing ( Rear bearing ).


Includes:

• bearing, o-ring and sealing ( Rear bearing ).

Securing screw in the shaft.

M16 x 180

Locking liquid must be used when fitting the screw (Loctite

243)!

3HAC028920-001

3HAC15571-1 Content is defined in section


.


Check for dissonance

The check points are shown in the figure

Inspection points, balancing device on page 144

.

1

Check for dissonance from...

• bearing at the link ear

• bearings at the balancing devices attachments.

If dissonance is detected...

... 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 297 .

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

Required equipment on page 145 .





3 Maintenance


Continued

2

3

Check for dissonance from...

If dissonance is detected...

• 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 (design 1) on page 302

. This section also specifies the spare part number!

• 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

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.



Check for leakage - Design 1

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!





3 Maintenance


Continued

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

xx0700000111

A

B

C

D

1

2

3

Shaft

Sealing ring (radial) 2 pcs

O-ring

Sealing spacer

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.

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

Required equipment on page 145

.

The replacement of the complete bearing is also detailed in section


Check for leakage - Design 2

The front ear of the balancing device is lubricated with grease.

Leaks at o-rings, sealings etc. are not acceptable and must be attended to immediately to avoid damage to the bearing.





147

3 Maintenance


Continued

Check the o-rings and sealings in the front ear of the balancing device for leaks.

xx1000000207

A

B

C

D

1

2

Shaft

Sealing ring (radial (2 pcs)

O-ring

Sealing spacer

Action

Clean the area at the front ear from contamination.

Note

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

3

DANGER

Turn off all:




4

5

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

Replace o-rings if leaks are detected.

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


.

Replacement of the complete bearing is also described in section






3 Maintenance


Continued

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.




149

3 Maintenance

3.3.8 Inspecting the cable harness

3.3.8 Inspecting the cable harness

Introduction

This section describes how to inspect the cable harness. The procedure is divided in two parts:

• Inspection of axes 1-4 is described in:

Location of cable harness, axes 1-4 on page 151

and

Inspection, cable harness 1-4 on page 152

.

• Inspection of axes 5-6 is described in:

Location of cabling axes 5-6 on page 153

and

Inspection, cable harness, axes 5-6 on page 153

.





3 Maintenance


Continued

Location of cable harness, axes 1-4

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

IRB 6640 Standard xx0600003434

A

B

C

Lower arm

SMB/BU unit (battery pack RMU 3HAC16831-1 is shown, note that there are different battery versions)

Connectors at base





151

3 Maintenance


Continued


Equipment, etc.

Standard toolkit


Circuit diagram

-

Art. no.

Note



.


See chapter

Circuit diagrams on page 489

.

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

Turn off all:



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

Check the connectors at the base .

Shown in the figure


.

4

Note

If the robot is used in a Foundry Prime application, check the cables for cracks in insulation.

5 Check that velcro straps are properly attached to the side bracket balancing cylinder .

Location shown in the figure

Location of cable harness, axes 1-4 on page 151 .

Note

For Clean Room robots, check all cable attachments as well as velcro straps .

Make sure the cable harness is properly attached to the robot and isn’t damaged.

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

Detailed in section

Replacing cable harness, axes 1-6 on page 222 .





3 Maintenance


Continued

Location of cabling axes 5-6

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

IRB 6640 standard xx0600003435

A

B

C

Cable harness axes 5-6

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:



2

3

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.

Shown in the figure

Location of cabling axes 5-6 on page 153 .





3 Maintenance


Continued

4

Action

Note

If the robot is used in a Foundry Prime application, check the cables for cracks in insulation.

Note

Shown in the figure


.

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

See

Replacing cable harness, axes 1-6 on page 222 .

See

Replacement of cabling, axis 5 motor on page 237

.




3 Maintenance

3.3.9 Inspection of air hoses (Foundry Prime)

3.3.9 Inspection of air hoses (Foundry Prime)

General

The air hoses on Foundry Prime robots must be inspected for leakage every six months.


Equipment, etc.

Leak detection spray

Pressure gauge

Cut off valve

Procedure

-

-

-

Art. no.

For this test it is recommended that the air supply to the robot has a pressure gauge and a cut-off valve connected.

1

Action Note

Apply compressed air to the air connector on robot base, and raise the pressure with the knob until the correct value is shown on the pressure gauge.

Recommended pressure:

0.2-0.3 bar

2 Close the cut off valve.

3

4

5

The time is < 5 seconds:

• If the answer is YES : Localize the leakage by following the procedures below.

• If the answer is NO : The system is OK.

Remove the leak testing equipment.

Pressurize by opening the cut off valve.

Spray suspected leak areas with leak detection spray.

xx0600002794

• A: Air Connection

• B: Cut off valve

• C: Pressure gauge

It should take at least 5 seconds for the pressure to reach 0 bar.

Note

Bubbles indicate a leak.

6 When the leak is localized: correct the leak.




155

3 Maintenance

3.3.10 Inspection of surface treatment (Foundry Prime)

3.3.10 Inspection of surface treatment (Foundry Prime)

Introduction to inspection of surface treatment

Damage to painted surfaces must be repaired as soon as possible to avoid corrosion. All painted surfaces on the robot must be inspected.


Equipment, etc.

Touch up paint Foundry Prime 2, grey

Note

See Touch up paint for Foundry Prime robots in partlist


Additional equipment - Foundry Prime

Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush

Foundry Prime touch up kit

Article number

3HAC034903-001

3HAC026759-001

12340011-116

3HAC035355-001

Note

Mercasol. Recommended drying time is 24h.

Inspection and repair of surface treatment

Use this procedure to inspect the surface treatment on Foundry Prime robots.

1

2

Action

Inspect all painted surfaces for damages.

Repair damages as described in the instruction included in the spare part kit.

Information




3 Maintenance

3.3.11 Inspecting the information labels

3.3.11 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

Safety symbols on product labels on page 43 .

xx0600003457

-

J

M

I

A

B

C

Warning label concerning high temperature (4 pcs)

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

Instruction label

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

Warning label concerning shutting off power

Serial no. from rating label

Information labels about type of oil, at gearboxes and at robot base





157

3 Maintenance

3.3.11 Inspecting the information labels

Continued

M

K

E

N

G

H

Warning

F xx0600003456

L

M

H

K

N

P

Q

E

F

G

Instructional label concerning lifting the robot

Warning label concerning risk of tipping

Foundry logotype

Warning label concerning stored energy

Abs-Acc information sign

UL-label

Serial no. from rating label

Label calibration

Warning label

Label Max air pressure

Q

P Warning

L

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

Spare parts on page 487 .




3 Maintenance

3.3.12 Inspecting the axis-1 mechanical stop pin

3.3.12 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.

Location of mechanical stop pin

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

xx0600003436

A

B




Visual inspection, no tools are required.





159

3 Maintenance

3.3.12 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 Maintenance

3.3.13 Inspecting the additional mechanical stops

3.3.13 Inspecting the additional mechanical stops

Location of mechanical stops

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

3.

xx0600002938

A

B

C

D

Additional stop, axis 1

Attachment screws and washers (2 pcs)

Fixed stop






161

3 Maintenance



C

D

A

B


Fixed stop, axis 3


Fixed stop, axis 2


Equipment etc.

Article number


Mechanical stop axis 2

Standard toolkit -

3HAC13787-1


Note

Includes:

• Stop +15°/-7.5°

• Stop +7.5°/-15°

• Attachment screws plus washers

• Document for movable mechanical stop

Includes:

• Mechanical stop

• Attachment screw and washer

• Document for mechanical stop

Includes:

• Mechanical stop pin

• Attachment screw and washer

• Document for mechanical stop pin



.





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 161 .

Make sure the stops are properly attached.

Correct tightening torque, additional mechanical stops:

• Axis 1 = 120 Nm.

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

Correct attachment screws:

• Axis 1: M12 x 40, quality 12.9.

• Axis 2: M16 x 50

• Axis 3: M16 x 60

Article number is specified in





163

3 Maintenance

3.3.14 Inspecting the damper on axes 2-5

3.3.14 Inspecting the damper on axes 2-5

Location of dampers

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

xx0600003440

A

B

C

D

Damper, axis 2 (2 pcs)

Damper, axis 3 (2 pcs)

Damper, axis 4 (1 pc)

Damper, axis 5 (2 pcs) (IRB 6640ID: 4 pcs)


A damper must be replaced if damaged!

Equipment

Damper axis 2

Damper axis 3

Damper axis 4

Damper axis 5

Damper 1, axis 5

Damper 2, axis 5

Standard toolkit

Spare part/ art. no.

3HAC12991-1

3HAC12320-1

3HAC13564-1

3HAB4337-2

3HAC021325-001

3HAC021675-001

3HAC15571-1

Note

IRB 6640ID (2 pcs)

IRB 6640ID (2 pcs)







3 Maintenance

3.3.14 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 164 .

Check attachment screws for deformation.

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

Art. no. is specified in


.




165

3 Maintenance

3.3.15 Inspecting the signal lamp (option)

3.3.15 Inspecting the signal lamp (option)

Location of signal lamp

The signal lamp is located as shown in this figure.

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.

xx0600003071

A

B

C

D

E

UL signal lamp

Clamp

Cable strap, outdoor

Motor, axis 3

Attachment screw, M6x8 quality 8-A2F (2 pcs)


Equipment

Signal lamp kit

Standard toolkit -


See


To be replaced if damage is detected.



.





3 Maintenance

3.3.15 Inspecting the signal lamp (option)

Continued

Inspecting, signal lamp

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

1

Action

Inspect 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:

• inspecting whether the signal lamp is broken.

If so, replace it.

• inspecting cable connections.

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

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


Required tools and equipment on page 166

.




167

3 Maintenance

3.4.1 Type of lubrication in gearboxes

3.4 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.

C

D

E

F

B

A xx0600003442

A

B

C

D

Gearbox, axis 1

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 4





Equipment

3 Maintenance

3.4.1 Type of lubrication in gearboxes

Continued

E

F

Gearbox, axis 5

Gearbox, axis 6

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)




169

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.

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

A

B

C xx0600003449

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil

Oil collecting vessel

Oil exchange equipment

Standard toolkit -

Art. no.

See


.

-

3HAC021745-001

Amount Note

See


.

Note


Capacity: 8,000 ml.


Special tools on page 466

.







3 Maintenance


Continued

CAUTION



.

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

5

Collect drained oil in an oil vessel.

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

Open the oil plug for draining and drain the oil into a vessel.

Vessel capacity is specified in


.

Shown in figure

Location of oil plugs on page 170 .

Note

CAUTION

Drain as much oil as possible. See


.

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

6 Refit the oil plug, draining .





171

3 Maintenance


Continued

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 170

.

Refill the gearbox with clean lubricating oil.

The correct oil level is detailed in section

Inspecting the oil level in axis-1 gearbox on page 127

.



.

5

Note

Do not mix Kyodo Yushi TMO 150 with other oil types!

6 Refit the oil plug, filling.





3 Maintenance



Location of oil plugs

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

xx0600003451

A

B

C


Oil plug, filling

Oil plug, draining


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.



.



CAUTION



.





173

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 39

.

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 oil plug for inspection .

Shown in the figure

Location of oil plugs on page 173

.




.



5

Note

Don´t mix Kyodo Yushi TMO 150 with other oil types!






175

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

3 Maintenance


Continued

Equipment, etc.

Standard toolkit -

Art. no.

Amount Note



CAUTION



.

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.






177

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

Note







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.



.

CAUTION



.





179

3 Maintenance


Continued

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.

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:








3 Maintenance


Continued

Action Note

2

3

4

WARNING






.

Refit the oil plug, filling.

Shown in the figure


.







181

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 466 .

Capacity: 7,000 ml.



CAUTION


Cut the paint or surface on the robot before replacing parts on page 219 .





3 Maintenance


Continued

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.

2

DANGER

Turn off all:




3

WARNING




.

4

5

6


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




.





183

3 Maintenance


Continued

Action Note

3

4

5

DANGER

Turn off all:







Shown in the figure


.



Refit the oil plug, filling.





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

7,000 ml (IRB 6640ID)



CAUTION



.





3 Maintenance


Continued

Draining, oil, axis 6

The procedure below details how to drain oil from the gearbox, axis 6.



1

Action Note

IRB 6640:

Run the robot to a position where the oil plug, filling of axis 6 gearbox is facing downwards.

IRB 6640ID:

Run axis 4, to calibration position, and lower the upper arm to a comfortable position.

Shown in the figure


2

DANGER

Turn off all:




3

4

5

WARNING




.

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:








3 Maintenance


Continued

Action Note

2

3

4

5

6

WARNING




.

Remove the oil plug, filling.

Shown in the figure


.




.



Note


Type of lubrication in gearboxes on page 168 .


Refit the oil plug.

Inspect the oil level.







187

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 38

.

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) xx0600003444

A

B

C

D

Cover, battery box

SMB battery pack with 2-pole battery contact.

Cable, battery

Battery holder





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.







3 Maintenance


Continued

Equipment, etc.

Circuit diagram -

Spare part no.

Note

See chapter

Circuit diagrams on page 489

.

Removing, battery

Use this procedure to remove the SMB battery.

1

Action

Move the robot to its calibration position.

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 34

4

CAUTION



5 Remove the SMB battery cover by unscrewing the attachment screws.

Shown in figure

Location of SMB battery on page 188 .

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards which can result in hazardous failures.

6

7

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






3 Maintenance


Continued

Refitting, battery

Use this procedure to refit the SMB battery.

Action

1

DANGER

Turn off all:



2


Note

3

4



Clean the joints that have been opened. See


Reconnect the battery cable and install the battery pack into the SMB/battery recess.



Note

Shown in figure

Location of SMB battery on page 188

.

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.

5

6

7

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 188

.

Seal and paint the joints that have been opened.

See


Update the revolution counters.

Detailed in chapter Calibration section

Updating revolution counters on page 444 .





191

3 Maintenance


Continued

Action

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 29 .

Note




3 Maintenance

3.5.1 Analyzing the water content in gearbox oil

3.5 Analysis activities

3.5.1 Analyzing the water content in gearbox oil

Analysis of the water content

It is recommended to check for water content in the oil every 12 month.

Effect on gearbox replacement

The table shows what effect the analyze result has on the replacement interval of the gearbox.

1

If: Then....

More than 3% water in oil:

• With more than 3% water content there is a risk for corrosion in the gearbox and reduced viscosity in the oil.

Replacement of gearbox required every two years

A

3%

2 Less than 3% water in oil.

6 12 18 24 30

3000 6000 9000 12000 15000

B

C xx0600003155

• A: Water content in gearbox oil

• B: Months or hours in operation

• C: Replacement of gearbox

Normal replacement interval is required for the gearbox.

A

3%

6 12 18 24 30

3000 6000 9000 12000 15000 xx0600003156

• A: Water content in gearbox oil

• B: Months or hours in operation

B




193

3 Maintenance

3.6.1 Lubrication of spherical roller bearing, balancing device

3.6 Lubrication activities

3.6.1 Lubrication of spherical roller bearing, balancing device

Location of bearing (Design 1)

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!

xx0700000731

A

B

Securing screw and lubricating hole

Roller bearing

Location of bearing (Design 2)

Note

The spherical roller bearing of design 2 with solid-oil does not need any scheduled lubrication.





3 Maintenance


Continued

C

A

B xx0700000361

A

B

C

Upper securing screw/Lubrication hole

Lower securing screw

Spherical roller bearing


Equipment, etc.

Grease

Lubrication nipple

Art. no.

3HAC042534-001

Note

Optimol PDO, 20 ml

M6.

Normally not fitted to the link ear at delivery.

Grease pump -





195

3 Maintenance


Continued

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

4

5

Replace the securing screw at the link ear with a lubrication nipple.

M6

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

Required equipment on page 195 !

Shown in the figure

Location of bearing

(Design 1) on page 194

!


Remove the lubrication nipple and refit the 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 -

Check for leakage - Design 1 on page 146

.

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

3

4

5

Replace the upper securing screw at the link ear with a lubrication nipple.

M6

Remove the lower securing screw M6

Lubricate the spherical roller bearing through the lubrication nipple in the ear with grease.

Art. no. and amount is specified in

Required equipment on page 195 !

Fill until excessive grease is forced out through the hole of the lower securing screw.

Shown in the figure

Location of bearing

(Design 1) on page 194

!


Remove the lubrication nipple, and refit the upper securing screw and washer.

M6 x 10, washer: D=6,4/12 T=1,6






3 Maintenance


Continued

6

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 -


.




197

3 Maintenance

3.6.2 Rust preventive measures, bearing axis 1 (Foundry Prime)

3.6.2 Rust preventive measures, bearing axis 1 (Foundry Prime)

Location of bearing axis 1

The bearing axis 1 is located as shown in the illustration. (View from above).

xx0700000445

A Cable guide


Equipment

Brush


198

-

Art. no.

Note




Procedure

3 Maintenance


Continued

Equipment

Rust preventive

Sikaflex 521FC

Standard toolkit


Art. no.

3HAC034903-001

3HAC026759-001

Note

Equivalent:

• Mercasol

Option Foundry Prime




The following procedure details how to apply the rust preventive on bearing axis

1.

Action Note

1

DANGER

Turn off all:



2 Remove the cable guide.

3 Wipe the surface under the cable guide.

xx0700000445

Parts:

• A: Cable guide





199

3 Maintenance


Continued

4

Action

Apply rust preventive on the radial sealing with a brush.

Note

5

6

Refit the cable guide.

Apply Sikaflex 521FC outside the cable guide as shown in the figure.

xx1000000370

Parts:

• A: Mercasol

• B: Protection pipe

• C: Radial sealing xx1000000372

• A: Sikaflex 521FC

• B: Cable guide




3 Maintenance

3.6.3 Rust preventive measures, sealing axis 4 (Foundry Prime)

3.6.3 Rust preventive measures, sealing axis 4 (Foundry Prime)

Overview

The sealing axis 4 is located as shown in the illustration.

xx0600002869

A

B

Cover

Cable guide


Equipment

Brush

Rust preventive

Standard toolkit


-

Art. no.

3HAC034903-001

Procedure

Note

Equivalent:

• Mercasol




The procedure describes how to apply rust preventive on sealing axis 1.

1

Action

Put the robot in a suitable position.

Note





201

3 Maintenance


Continued

Action

2

DANGER

Turn off all:



3 Remove the cover at the rear end of the upper arm.

Note

4 Remove the cable guide that covers the sealing.

xx0600002872

Parts:

• A: Cover

• B: Cable guide

5 Wipe the surface under the cable guide .

xx0600002871

Parts:

• A: Cable guide





3 Maintenance


Continued

6

Action

Apply rust preventive on the radial sealing and the rear part of the tube with a brush.

Note

7 Refit the radial sealing and cable guide .

xx0600002868

Parts:

• A: Radial sealing and rear part of tube

• B: Cable guide




203

3 Maintenance

3.6.4 Rust preventive measures, support bearing in wrist (Foundry Prime)

3.6.4 Rust preventive measures, support bearing in wrist (Foundry Prime)

Location of bearing

The support bearing in the wrist is located as shown in the illustration.

xx0600002863

A

B

C

Bearing

Cable bracket

Cover


Equipment

Brush

Rust preventive

Standard toolkit


Article number

-

3HAC034903-001

Note

Equivalent:

• Mercasol



.






3 Maintenance

3.6.4 Rust preventive measures, support bearing in wrist (Foundry Prime)

Continued

Greasing bearings

The procedure describes how to apply rust preventive on the support bearing.

1

Action

Put the robot and the upper arm in a suitable position.

Note

2

DANGER

3

4

5

Turn off all:



Disconnect the air hose from motor axis 6.

Remove the hose clamp on motor axis 6, and remove the air hose.

Remove the cover with gasket.

A xx0600002864

• A: Cover

See

Location of bearing on page 204

.

6

7

Apply rust preventive on the bearing and cable bracket with the brush.

Refit the cover with gasket.

Note

Replace gasket if damaged.

8

9

10

Refit the hose clamp.

Connect the air hose to motor axis 6.

Perform a leakdown test.

See

Inspection of air hoses

(Foundry Prime) on page 155

.




205

3 Maintenance

3.6.5 Apply Mercasol on output shaft axis 2

3.6.5 Apply Mercasol on output shaft axis 2

Location of the gear axis 2

The gear axis 2 is located as shown in the illustration.

xx1500001662


Equipment

Brush

Required consumables

Consumable

Rust preventive isopropyl alcohol


Article number

3HAC034903-001

Note

Equivalent:

• Mercasol





Procedure

3 Maintenance


Continued

1

2

The procedure describes how to remove and apply rust preventive output shaft axis 2.

Action


Note

DANGER

Turn off all:



3 clean the surface on the output shaft with isopropanol.

A

B

4 Apply rust preventive on the out put shaft with a brush.

xx1500001660

A Gear axis 2

B Output shaft




207

3 Maintenance


3.6.6 Apply Mercasol on output shaft axis 3

Location of the gear axis 3

The gear axis 2 is located as shown in the illustration.

xx1500001667


Equipment

Brush


Required consumables

Consumable

Rust preventive

Article number

3HAC034903-001

Note

Equivalent:

• Mercasol

Procedure

The procedure describes how to remove and apply rust preventive output shaft axis 3.

1


208

Action


Note




3 Maintenance


Continued

Action

2

DANGER

Turn off all:



3 clean the surface on the output shaft with isopropanol.

Note

A

B

4 Apply rust preventive on the out put shaft with a brush.

xx1500001661

A Gear axis 2

B Output shaft




209

3 Maintenance

3.7.1 Cleaning the IRB 6640 Foundry Prime

3.7 Cleaning activities

3.7.1 Cleaning the IRB 6640 Foundry Prime

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 6640 Foundry Prime 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 6640 Foundry Prime.

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 127 .

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.

Oil spills discolors painted surfaces

Oil spills on painted surfaces of the robot can result in discoloration.

Note

After all repair and maintenance work involving oil, always wipe the robot clean from all surplus oil.

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.





3 Maintenance


Continued

• 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.

Cleaning methods

The following table defines what cleaning methods are allowed depending on the protection type.

i

Protection type

Foundry

Prime

Cleaning method

Vacuum cleaner

Yes

Wipe with cloth Rinse with water

Yes. With cleaning detergent approved by ABB, spirit or isopropyl alcohol.

See


.

Yes. It is highly recommended that the water contains a rust-prevention solution.

High pressure water or steam

Yes i

.

It is highly recommended that the water and steam contains rust preventive.

If cleaning detergents are used they must be approved by ABB for

Foundry Prime robots.

See


.

Perform according to section

Cleaning with water and steam on page 211 .

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

1

2

See

Cleaning methods on page 211

for exceptions.

See

Cleaning methods on page 211

for exceptions.





211

3 Maintenance


Continued

Additional cleaning instructions for Foundry Prime robots

Washing detergents

• Only washing detergents approved by ABB shall be used.

• The washing detergent must be cleansed continuously.

• The washing detergent must contain rust inhibitor.

• The detergent pH value and concentration must be checked regularly.

• Maximum allowed pH of the washing detergent is 9.0, if not stated otherwise.

• The user must follow the recommendations regarding detergent concentration and pH value.

• No other additive than water is guaranteed without prior testing or agreement with ABB. Other additives than water may have a harmful effect on the life of the robot and its components.

• Recommendations given by the detergent manufacturer for the specific detergent in question must be followed.

Note

If the pH value or the detergent concentration is varying from its original specification, it can become very corrosive.

Approved cleaners and detergents

All cleaners and detergents must be approved by ABB before use. Contact ABB

Robotics Sales Support to get the latest released list of approved cleaners and detergents.

Temperature of cleaning bath

• Maximum temperature <60ºC.

Ambient temperature must not be higher than +50° C.

Note

Make sure that the special Foundry Prime painting of the robot is not broken during testing, installation, or repair work. Use the touch up kit available for

Foundry Prime (article number 3HAC035355-001) to repair any damages in the paint.

Washing without detergent

If the washing is performed without detergent, the water must contain rust inhibitor.

Cables

Movable cables need to be able to move freely:

• Remove waste material, such as sand, dust and chips, if it prevents cable movement.

• Clean the cables if they have a crusty surface, for example from dry release agents.




4 Repair

4.1 Introduction

4 Repair


Structure of this chapter

This chapter describes all repair activities recommended for the IRB 6640 Foundry

Prime 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 457

.


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 19

before commencing any service work.

Note

If the IRB 6640 Foundry Prime is connected to power, always make sure that the

IRB 6640 Foundry Prime is connected to earth before starting any repair work.

For more information see:





213

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.




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.





215

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.




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 onto the robot.

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 217 .

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.





217

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.




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.

When replacing parts on a robot with protection type Foundry Prime, it is important to make sure that after the replacement, no surface without paint is exposed to the aggressive working environment.


Equipment

Sealing compound

Tooling pin

Cleaning agent

Knife

Lint free cloth

Spare parts

Rust preventive

Brush

Touch up paint Foundry Prime /

Foundry Prime 2 / Foundry Prime

3, Grey

3HAC035355-001

Note

Sikaflex 521 FC. Color white.

Width 6-9 mm, made of wood.

Ethanol

Mercasol

The grey touch up paint is used on all Foundry Prime robots, regardless of the original color of the robot.

Removing

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

Refitting

1

2

Action

Before the parts are refitted, clean the joint so that it is free from oil and grease.

Place the tooling pin in hot water.

Description

Use ethanol on a lint free cloth.





4 Repair

4.2.4 Cut the paint or surface on the robot before replacing parts

Continued

3

Action

Seal all refitted joints with Sikaflex 521FC.

Description

4 Use the tooling pin to even out the surface of the Sikaflex seal.

xx0900000122 xx0900000125

5

6

Wait 15 minutes.

Use Touch up paint Foundry Prime, grey to paint the joint.

Sikaflex 521FC skin dry time (15 minutes).

3HAC035355-001

Note

Always read the instruction in the product data sheet in the paint repair kit for Foundry

Prime.

7 Apply Mercasol on all screw heads and set screws after tightening.




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.




221

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.

Location of cable harness

The cable harness of axes 1-6 is run throughout the robot as shown in the figure below.

xx0700000102

C

D

E

A

B

Connectors at motor, axis 2 (R2.FB2, R2.MP2)

Connectors at motor, axis 1 (R2.FB1, R2.MP1)

Rear cover plate

Earth (attachment point is placed under the cover plate)

Cable harness





J

K

L

F

G

H

O

P

M

N

R

4 Repair


Continued

Cable holder

Velcro strap

Guide plate ax 2

Cable guide

Connector R1.MP

Connector R1.SMB

Cable protector (placed inside the lower arm)

Position for SMB and brake release units

Cable harness (cut away view)

Velcro strap (inside lower arm on metal clamp)

Cable gland (armhouse)

Required parts xx0700000107

Equipment

Cable harness, axes 1-6

Spare part no.

See Spare parts chapter.

Gasket

Gasket, cover

3HAC3438-1

3HAC033489-001

Note

Includes:

• Gaskets axes 1-5

Motors axes 1-5

Motor axis 6





223

4 Repair


Continued

Required equipment - tools etc.

For Foundry Prime robots also see

Additional equipment - Foundry Prime on page 224

.

Equipment

Locking screw

Standard toolkit

Circuit diagram

Note

M16x60 quality 12.9 Gleitmo

For securing the lower arm



See chapter:

• Circuit diagram


Equipment

Rust preventive

Rust preventive

Sikaflex 521FC

Brush

Art. no.

3HAC026621-001

-

3HAC034903-001

3HAC026759-001

Note

Equivalent:

• Mercasol

Mercasol

CAUTION



Cable brackets of the upper arm xx0500002293

A

B

C

Cable bracket, wrist unit

Cable bracket, upper arm tube

Cable attachment, rear





4 Repair


Continued

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.

2

DANGER

Turn off all:




3

CAUTION



.

4 Remove the cover, wrist unit and the cover, upper arm tube .

5

Note

Axis 5 must be oriented in the correct position

(+90º) to allow the motor 6 cover to open!

6 Remove the cover of motor, axis 6 and disconnect all connectors beneath.

xx0200000214

A Cover, wrist unit

B Cover, upper arm tube





225

4 Repair


Continued

7

Action Note

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 224

.

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


.

10

11

12

Disconnect the two

R3.MP5) connectors (R3.FB5 and inside the tube.

Shown in the figure

Location of cable harness on page 222

.

Remove cable straps from the harness, if any.

Remove the cable attachment, rear.

Shown in the figure


.

13

14

15

16

Remove the covers of motors axes 3 and 4 and disconnect all connectors beneath.

Pick out the cabling from the motors.

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.

Action Note

1

CAUTION



2

3

4

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

.

Position shown in the figure

Shown in the figure

harness on page 222

.


.

Location of cable





4 Repair


Continued

5

6

7

8

9

Action

Remove the cable holder on the frame securing the cable harness.

Pull the cable and connectors up through the cable guide in the center of the frame.

Note

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!

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.

xx0700000104





227

4 Repair


Continued

10

Action

Remove the cable gland by removing the attachment screws from inside the SMB recess.

Note

11 Remove the velcro strap and cable gland.

xx0700000109

• A: Cable gland

• B: Attachment screws, inside

SMB recess (4 pcs)





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

5 xx0100000143

Remove the velcro strap from the harness at the guide plate ax 2 at the lower arm.

Shown in the figure


.

Remove the cable harness from the axis-2 cable guide plate.

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 233

.

Action

1

Note

Note

For art. no. see:

•

Additional equipment - Foundry

Prime on page 224

Apply rust preventive around all dismantled covers and attachment screws with a brush.





229

4 Repair


Continued

Action Note

2

3

4

5

6

7

8

9

Note

Always apply rust preventive (Mercasol) on covers, attachment plates and screws after refitting these components.



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!

Reconnect the earth cable .

Position shown in the figure


.

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.

Note

For art. no. see

•

Required parts on page 223

On Foundry Prime robots:

When dismantling the cables from the motors, the gasket must be replaced.





4 Repair


Continued

10

Action

Foundry Prime robots:

Apply Sikaflex 521FC on the cover located on the cable harness at the SMB/BU units before the harness is fitted.

Note xx1000000386

Parts:

• A: Position for cover in SMB recess

• B: Sikaflex 521FC

• C: Cover





231

4 Repair


Continued

11

Action

Secure the cable gland with its attachment screws from inside the SMB recess.

Refit the velcro strap . (Shown in the figure


.)

Note

12 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.

xx0700000109

• A: Cable gland

• B: Attachment screws, inside

SMB recess (4 pcs)

13 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.

xx0700000104





4 Repair


Continued

Action

14

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 221

!

Note

15

16

Push the cable harness gently through the lower arm.

Refit the metal clamp on the inside of the lower arm.

Then refit the cable harness to the metal clamp with the velcro strap and cable gland.

xx0100000142

17 Seal and paint the joints that have been opened. See


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 229

.

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 229 .







233

4 Repair


Continued

3

Action

Refit the cable gland securing the cables in the armhouse.

Note

Shown in the figure


.

Note

The cable harness is delivered pretwisted.

Make sure not to affect this by twisting the cable harness further in any direction.

xx0100000143

4

5

6

7

8

Reconnect all connectors on motors axes 3 and 4.

Secure 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


.

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 224 .

9

Note

The position of axis 6 must be +90° for a correct installation of the cable harness.





4 Repair


Continued

10

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

11 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

12

13

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.

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

14

15

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 224 .







4 Repair


Continued

17

Action Note

If the connection between the SMB battery and the SMB unit has been broken, the revolution counters now must be updated!

Detailed in section


18

DANGER






4 Repair

4.3.2 Replacement of cabling, axis 5 motor

4.3.2 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:








237

4 Repair


Continued

Action Note

2

3

4

5

6

7

CAUTION



.

Remove the complete wrist unit.

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.

Detailed in section:

• IRB 6640:

Removal, wrist unit on page 265 .

Refitting, cabling axis 5 motor

The procedure below details how to refit the cabling to the motor of axis 5.

Action Note

1

DANGER

Turn off all:




2

5

6

3

4

7

8



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.

Detailed in section:

• IRB 6640:

Refitting, wrist unit on page 266 .

Seal and paint the joints that have been opened. See


Re-calibrate the robot.

Calibration is detailed in a separate calibration manual enclosed with the calibration tools.

General calibration information is included in section

Calibration information on page 439 .





4 Repair


Continued

9

Action

DANGER



Note




239

4 Repair

4.3.3 Replacement of complete arm system

4.3.3 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


.

xx0700000352

C

D

E

F

G

A

B

Upper arm

Lower arm

Frame

Base

Gearbox, axis 1

Attachment screws base M12x80, quality 12.9 Gleitmo (16 pcs)

Motor, axis 1


Equipment, etc.

Holder for bits

Art. no.

3HAC029090-001

Note

Bits SW10 included





4 Repair


Continued

Equipment, etc.

Guide pins M12 x 130

Roundsling 2 m

Roundsling 1,5 m

Hoisting block

Lifting chain

Isopropanol

Standard toolkit


-

-

-

-

Art. no.

3HAC022637-001

Note

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 2,000 kg

Lifting capacity 1,000 kg

Lifting capacity 500 kg

Used to adjust the length of the lifting chain.

Used together with the hoisting block.

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:

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.

Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values.

Creating new values requires possibility to move the robot.

Read more about reference calibration for

Pendulum Calibration in Operating manual - Calibration Pendulum .

If the robot is to be calibrated with fine calibration:

Remove all external cable packages

(DressPack) and tools from the robot.





4 Repair


Continued

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


3 Run the overhead crane to a position above the robot.

xx0700000351





4 Repair


Continued

4

Action Note

Fit the lifting accessory .

Also fit a hoisting block to the roundsling put around the lower arm. Used to adjust the balance of the arm system in order to lift it completely level.

Make sure the lift is done completely level!

C

B

A

D

E

Note

There is an alternate method of lifting the complete armsystem described below.

H

F

G xx0700000349

A: Lifting eye (on arm house)

B: Lifting chain

C: Hoisting block

D: Lifting chain

E: Roundsling (put in a loop around the wrist on the inside)

F: Roundsling (used to eliminate any load through the brake on motor axis 3)

G: Position for roundsling F, inserted through hole in the frame

H: Roundsling (put in a loop around the lower arm)





243

4 Repair


Continued

5

Action Note

Alternate lifting method, with no need of using a hoisting block.

1 Run axis 2 to -60° and axis 3 to approximately

+60°.

2 Fit the lifting accessories according to the figure to the right.

3 Run axis 3 so that the roundsling E is stretched.

4 Raise the lifting accessories to tension the chains and verify that the center of gravity is approximately 75 mm behind of the axis-1 center.

A

B

C

D

E

6

DANGER

Turn off all:




F xx1200000670

• A: Lifting eye (on arm house)

• B: Lifting chain

• C: Lifting chain

• D: Roundsling (put in a loop around the wrist on the inside)

• E: Roundsling (used to eliminate any load through the brake on motor axis 3)

• F: Position for roundsling E, inserted through hole in the frame

7

CAUTION



8

9

Drain the oil from gearbox axis

1.

Detailed in section


.

Disconnect the cabling in the rear of the robot base and remove the cable support plate inside the base.





4 Repair


Continued

Action Note

10 Pull the disconnected cabling up through the center of the axis-1 gearbox.

How to replace the cabling is detailed in

Replacing cable harness, axes 1-6 on page 222

.

11 Remove the motor, axis 1.

Detailed in section

Replacing motor axis 1 on page 339 .

12 Remove the calibration plate from the bottom of the frame.

13 Remove the mechanical stop pin from the frame.

xx0700000380

Parts:

• A: Calibration plate

A xx1200000668

A Mechanical stop pin





245

4 Repair


Continued

Action

14 Unfasten the arm system from the base by unscrewing its 16 attachment screws.

Note

Shown in the figure

Location of arm system on page 240

.

xx0600003070

Parts:

• A: Serrated lock washer

• B: Gearbox axis 1

• C: Attachment screws M12x80

15 Fit two guide pins in two opposite screw holes.



.

16

CAUTION

The complete arm system weighs 1250 kg! All lifting equipment used must be sized accordingly!

17 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.

Refitting, arm system

The procedure describes how to lift and refit the complete arm system.

Action Note

1

DANGER

Turn off all:




2 Clean the joints that have been opened. See






4 Repair


Continued

3

Action Note

Fit the lifting accessory as detailed in the figure to the right.

Also fit a hoisting block to the roundsling put around the lower arm.

(Used to adjust the balance of the arm system in order to lift it completely level!)

Note

There is an alternate method of lifting the complete armsystem described below!




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


C

B

A

D

E

F

H

G xx0700000349



• C: Hoisting block

• D: Lifting chain

• E: Roundsling (put in a loop around the wrist on the inside)

• F: Roundsling (used to eliminate any load through the brake on motor axis 3)

• G: Position for roundsling F, inserted through hole in the frame

• H: Roundsling (put in a loop around the lower arm)





247

4 Repair


Continued

4

Action Note

Alternate lifting method, with no need of using a hoisting block.

1 Run axis 2 to -60° and axis 3 to approximately +60°.

2 Fit the lifting accessories according to the figure to the right.

3 Run axis 3 so that all the roundslings are stretched.

4 Verify that the center of gravity is approximately 75 mm behind of the axis-

1 center.

A

B

C

D

E

5

CAUTION

The complete arm system weighs 1250 kg!

All lifting equipment used must be sized accordingly!

F xx1200000670



• C: Roundsling (used to pick up the load of the arm system)



• F: Roundsling (used to eliminate any load through the brake on motor axis 3)

• G: Position for roundsling F, inserted through hole in the frame

• H: Roundsling (put in a loop around the lower arm)

6

7

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.





4 Repair


Continued

8

Action Note

Fit two guide pins in the holes in the axis-1 gearbox, as shown in the figure to the right.

If using guide pins of different lengths, fit the pin with maximal length of 130 mm on the right side of the gearbox (seen from behind).

Dimension is specified in


.

Note

Lubricate the guide pins for easier fitting of the arm system.

xx0600003095

The figure below shows the gearbox, axis

1.

A Attachment holes for guide pins,

M12 in gearbox axis 1.

B Hole for attachment screw.

9 Lubricate the outer surface of the gearbox for easier mating of the gearbox and arm system.

10 Look through the empty mounting hole of motor 1 to assist in aligning the assembly during refitting of the arm system.

Lower the arm system with guidance from the guide pins previously fitted to the axis-

1 gearbox axis 1. Fit the guide pins in the corresponding holes in the frame as shown in the figure to the right.

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.

xx0600003093

• A : Holes in frame for guide pins, shown from above.





249

4 Repair


Continued

Action

11

Note

Check that the serrated lock washers are turned the correct way. See figure!

Note xx0600003070

Parts:



• C: Attachment screws M12x80

12 Refit 14 of the 16 attachment screws before the arm system is completely lowered.

Note

Use a torque wrench with a holder for bits recommended in

Replacement of complete arm system on page 240

.

13 Remove the guide pins and secure the arm system to the base with its 16 attachment screws and washers.

Shown in the figure

Location of arm system on page 240 .

M12 x 80, 12.9 quality gleitmo. Tightening torque: 105 Nm.

Reused screws may be used, providing they are lubricated as detailed in section

Screw joints on page 461

before fitting.

14 Refit the calibration plate at the bottom of the frame.

xx0700000380

Parts:

• A: Calibration plate

15 Refit the mechanical stop pin to the frame.

16 Refit the axis-1 motor .

Detailed in section

Replacing motor axis

1 on page 339

.

17 Perform a leak-down test of the axis-1 gearbox.

18 Refit the cabling in the base.

19 Refill the gearbox with lubricating oil.

Detailed in section

Detailed in section

Performing a leakdown test on page 214

.


.

Detailed in section


.





4 Repair


Continued

Action



21 Recalibrate the robot.

Note

Pendulum Calibration is described in Operating manual - Calibration Pendulum , enclosed with the calibration tools.


Calibration information on page 439

.

22

DANGER






251

4 Repair

4.3.4 Replacement of air nipple and hose (Foundry Prime)

4.3.4 Replacement of air nipple and hose (Foundry Prime)

Location

The illustration below shows the routing of the Foundry Prime air hose.

xx0600003025

Hose lengths and parts

See hose lengths and parts in the figure and the following tables.

E D xx0700000449





4 Repair


Continued

Hose lengths

Parts

Location on the robot f e g a b c d j h k m n

1M

1N

1P

1Q

1R

1H

1K

1L

1S

1T

1U

1A

1B

1C

1D

1E

1F

1G

A

B

C

D

E

Hose length 50 mm

Hose length 50 mm

Hose length 1520 mm

Hose length 1090 mm

Hose length 310 mm

Hose length 45 mm

Hose length 250 mm

Hose length 540 mm

Hose length 4020 mm

Hose length 195 mm

Hose length 50 mm

Hose length 40 mm

Hose length 1605 mm

Hose length 100 mm (for option 2.8 m/185 kg: 350 mm)

Hose length 1490 mm (for option 2.8 m/185 kg: 1740 mm)

Hose length 570 mm

Hose length 100 mm

Hose length 50 mm

Pneumatic hose

Y-plug connector

T-plug connector

Check valve

Straight fitting

Balancing cylinder, rear end

Motor axis 1

Battery cover

Motor axis 2

Length = Pos 1S

Motor axis 6

Rubber clamp on attachment plate (tilthouse)

Rubber clamp on wrist cover

Motor axis 5

Motor axis 3

Motor axis 4

Bulkhead plug connector in plate at base





253

4 Repair


Continued


Equipment

Velcro strap

Cable straps

Elbow fitting

Rubber clamp

T-plug connector

Y-plug connector

Bulkhead plug connector

Hose

Art. no.

3HAC12625-1

21662055-3

3HAC026511-001

3HAC026523-001

3HAC026515-001

3HAC026514-001

3HAC026513-001

3HAC026526-001

2

1

Pos. in illustration

9 (only in illustrations below)


4

3


5

CAUTION



Procedure

The following procedures details how to replace the Foundry Prime air nipples and hose. The pos. no. in following procedures correspond to the illustration in

Hose lengths and parts on page 252

and the table in


Action Note

1

DANGER

Turn off all:




2

3

Locate the damaged hose or air connector, and continue to replace the damaged hose.

Route the hose according to the illustrations in the procedure below.

Connection at base.


254 xx0600003042

Items in illustration are detailed in


and


.




4

Action

Axis 1

4 Repair


Continued

Note xx0700000458

Items in illustration are detailed in


and


.

5 Balancing device.

Note

Always install the check valve with the arrow pointing upwards.

xx0700000459

Item in illustration is detailed in


1C xx1500000355

Item in illustration is detailed in


.





255

4 Repair


Continued

6

Action

Axis 1-2

Note

Items in illustrations are detailed in


and


.

xx0700000460 xx0700000461 xx0700000462

• A: Air hose beneath velcro strap





7

Action

Upper arm housing.

4 Repair


Continued

Note xx0600003046

8 Tube shaft.

xx0600003047

Replace_hose

• 1P: Lay the hose in a spiral in the tube shaft.





257

4 Repair


Continued

9

Action

Wrist.

Note

Make sure the cable length from 5a to the nipple of axis 6 = S, see

Replacement of air nipple and hose (Foundry Prime) on page 252

.

Note

1R xx1500000356

5a




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.

xx0300000473

A

B

E

Turning disk (type 1)

Wrist unit

Attachment screws (6 pcs) , turning disk xx0200000217

A

B

C

D

F

Turning disk (type 2)

Wrist unit

Oil plug, draining

Oil plug, filling

Attachment screws (12 pcs)





259

4 Repair


Continued


Equipment, etc.

Turning disk

O-ring

Wrist, type 1

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.

Art. no.

For spare part no.

see:


.

Note

O-rings are not included!

3HAB3772-65 (1pc)

21520431-20 (6 pcs)

Must be replaced when replacing the turning disk!

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



.


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 259

.

2

DANGER

Turn off all:



3

CAUTION



.

4

5

6

7

8

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 259

.





4 Repair


Continued

Refitting, turning disk

Use this procedure to refit the turning disk.

1

2

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.



.

3 Foundry Plus:

Apply Loctite 574 flange sealant on the contact surface.

xx0200000218

• A: Sealing surface, o-ring

4 Secure the turning disk with its attachment screws .

xx1400000995

The number of attachment screws depends on which wrist type is used:

6 pcs, M14 x 25

Tightening torque: 174 Nm.

12 pcs, M12 x 30, 12.9 quality Gleitmo.

Tightening torque: 100 Nm.



before fitting.





4 Repair


Continued

5

6

Action

Perform a leak-down test of the gearbox axis

6.

Refill the axis 6 gearbox with oil.

Note


Performing a leak-down test on page 214

.

See section

•


7

8

Refit any equipment removed during disassembly to the turning disk.



9

DANGER






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.



.

xx0700000343

F

G

D

E

I

H

A

B

C

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


Equipment etc.

Wrist unit

Art. no.

For spare part number, see


.

Note





4 Repair


Continued

Equipment etc.

Cover for wrist unit

Gasket for wrist house cover 3HAC043225-001

Gasket for cable cover on upper arm tube

Art. no.



.

Note

3HAC043224-001

Gasket for small cover on upper arm tube

3HAC043303-001

For robots with protection Foundry

Plus and Foundry Prime.

For robots with protection Foundry

Plus and Foundry Prime.

Gasket for cable cover on arm extender 250 mm

Gasket for cable cover on arm extender 450 mm


Lifting accessory, wrist unit

3HAC043302-001

3HAC043398-001

3HAC13056-3

3HAC13605-1

Should be installed for robots with protection Foundry Plus and

Foundry Prime.


Foundry Prime.


Foundry Prime.

Always use guide pins in pairs!

Standard toolkit Content is defined in section




Circuit diagram See chapter

page 489 .

Circuit diagrams on




1

Action Note















4 Repair


Continued

Action




Note

Removal, wrist unit

2

3

The procedure below details how to remove the complete wrist unit.

1

Action


Remove all equipment fitted to the turning disk.

Note

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

CAUTION



.

6

7

Remove the

Remove the cover, wrist unit .

cover, upper arm tube.

8 Remove the cover of motor, axis 6 and disconnect all connectors beneath.

Shown in the figure

Location of wrist unit on page 263 .

Shown in the figure






265

4 Repair


Continued

9

Action Note

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



10

11

Pick out the cabling from motor, axis 6 and place it safely on the tube.

Fit the lifting accessory to the wrist unit.

12

CAUTION

The complete wrist unit weighs 130 kg! All lifting equipment used must be sized accordingly!



.

13

14

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


15

16

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

Turn off all:




2

3



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 263

.





4 Repair


Continued

4

Action

Fit the lifting tool to the wrist unit.

Note

Art. no. is specified


.

5

CAUTION

The complete wrist unit weighs 130 kg! All lifting equipment used must be sized accordingly!

6

7

8

9

10

11

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


.

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

Axis 5 must be oriented in the correct position

(+90º) to allow the motor 6 cover to open!

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





267

4 Repair


Continued

13

Action Note

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


.

14

15

16

17

18

19 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.

For robots with protection type Foundry Plus and Foundry Prime: check the gasket. If damaged, or not previously installed, fit a new gasket.

Shown in the figure


.

Article number for the gasket is specified in


Refit the cover, wrist unit.

For robots with protection type Foundry Plus and Foundry Prime: check the gasket. If damaged, or not previously installed, fit a new gasket.

Shown in the figure


.

Tightening torque: 14 Nm±10%. Screw

3HAB3409-25 (with Loctite), Washer

3HAC062379-001.

Article number for the gasket is specified in




Re-calibrate the robot!

Pendulum Calibration is described in

Operating manual - Calibration Pendulum , enclosed with the calibration tools.



.

Refit any equipment previously removed from the turning disk.

20

DANGER



.




4 Repair

4.4.3 Replacement of support shaft with bearing axis 5

4.4.3 Replacement of support shaft with bearing axis 5

Introduction

This section describes how to replace bearing on support shaft axis 5.

Location of support shaft axis 5

The support shaft with bearing is located as shown in the figure below.


Equipment

Support shaft unit

Brush

Standard toolkit -

Art. no.

Note

-

See chapter:

• Spare parts

Includes:

• support shaft

• ball bearing

• sealing ring

-



.

CAUTION



.

Consumables

Consumable

Rust preventive

Locking liquid

Sealant

Article number

3HAC034903-001

3HAB7116-1

1234 0011-116

Note

Mercasol

Loctite 243

Loctite 574





4 Repair


Continued

Removing support shaft

1

Action

Turn axis 4 to a position where the cover, upper arm tube and wrist unit, faces upwards. Turn axis

5 to +90°.

Note

2 Relieve the pressure from the support shaft.

CAUTION

If there is a tool attached to the turning disk, be sure to place the tool in a safe manner.

3

4

DANGER

Turn off all:



Remove the cover, wrist unit with gasket.

Note

Disconnect the air hose from axis 6 motor.

xx0200000185

5

6

7 xx1500001685

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.

Open the cover on top of the axis 6 motor, and disconnect cable connectors.

Pick out the cabling from motor axis 6 through the support shaft, and place it safely on the tube.

xx0200000254







4 Repair


Continued

8

Action

Remove the six attachment screws.

Note

9 Install two screws in the threaded holes to pull the support shaft with bearing out.

xx1500001687 xx1500001688

Refitting support shaft

1

Action

Apply rust protection Mercasol on the edge on the new support shaft with bearing.

Note

2 Apply Loctite on surface A and Mercasol on surface B.

xx1500001693




xx1500001692

A Loctite 574

B Mercasol


271

4 Repair


Continued

3

4

Action

Place the new support shaft with bearing in place.

Align the bolt pattern.

Note

5

6 xx1500001686

Pull down the screws alternately until the shaft is seated.


Apply rust protection Mercasol on the support shaft and bearing.

7

8

9 xx1500001691

Reconnect cabling.

Refit cover to axis 6 motor.

Refit cover with gasket to wrist unit. Use M6x20 in hole closest to robot axis-6.

Note

Reconnect the "over pressure" air hose to axis 6 motor before tightening the cover.

Note

Replace gasket if damaged.

xx1500001685




4 Repair

4.4.4 Replacement of upper arm

4.4.4 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.





273

4 Repair


Continued



.

C

D

E

F

G xx0700000345

A

B

Attachment hole for lifting eye, M12 (if the 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

Motor, axis 3

Motor, axis 4

Attachment screws and washers, upper arm

Sealing, axes 2/3 (between lower arm and gearbox axis 3)


Equipment

Sealing, axis 3


274

Art. no.

3HAC17212-1

Note

Always use a new sealing when refitting the upper arm!




4 Repair


Continued

Equipment

Washer, axis 3 (3 pcs)

Foundry Prime (grey)

Art. no.

3HAC038648-001

Standard and Foundry Plus (ABB

Orange)

3HAC038648-002

Standard and Foundry Plus

(Graphite White)

3HAC038648-003

Guide pins, sealing axis 2/3 80 mm

3HAC14628-1

Guide pins, sealing axis 2/3 100 mm

Power supply -

3HAC14628-2

Rotation tool 3HAC17105-1

Note

To be replaced if damaged.



For guiding the axis-3 sealing.

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





275

4 Repair


Continued

Action Note











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 273 .

Rotate axis 5 to position +90°.

DANGER

Turn off all:




6

CAUTION



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






4 Repair


Continued

8

Action Note

Upper arm including wrist unit:

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 .



Attachment point is shown in the figure


Note

The different attachment points, depends on whether the wrist unit is mounted or not!

9

10 Drain the oil from gearbox axis 3.

Detailed in section


.

11 Remove the cover on top of the motors, axis 3 and

4 and disconnect all connectors inside the motors.

12 Remove the cable harness upper arm and place it in a way that it will not be damaged in the proceeding procedure of removing the upper arm.

Detailed in section

Removing the cable harness - upper arm on page 225 .

13

Fasten the lifting tool (chain) onto the lifting eye, the lifting accessory and an overhead crane.



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.

Note

When releasing the brake, the position of the upper arm is adjusted to the position given by the lifting equipment.

Connect to connector R2.MP3

• +: pin 2

• -: pin 5

16 Remove the axis-3 motor.

17 Carefully remove the attachment screws and washers, upper arm.

See

Replacing motor axis 3 on page 354 .

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






277

4 Repair


Continued

Refitting, upper arm

The procedure below details how to refit the upper arm.

1

2

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!



3

4 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:


ment on page 274 .

Required equip-

Attachment points are shown in the figure

Location of upper arm on page 273

.

Fit the lifting accessory, upper arm to the both attachments for the lifting accessory on the upper arm.

Note

The different attachment points, depends on whether the wrist unit is mounted or not!

5 Fasten the lifting tool (chain) onto the lifting eye, the lifting accessory and an overhead crane.







4 Repair


Continued

Action

6

CAUTION

The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting accessory to avoid injury to personnel!

Note

7 Lift the upper arm and move to its mounting position.

CAUTION


8

9

Fit in the gearbox attachment holes with the attachment holes on the lower arm with the guide pins.


ment on page 274 .

Required equip-

Fit the three washers to be placed beneath the attachment screws.

Shown in the figure


10 Insert 31 of the 33 attachment screws, upper arm into the attachment holes in the lower arm.

Do not remove the guide pins until the attachment screws are tightened as detailed below.

Shown in the figure


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.

11 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.

12 Remove the guide pins and fit the two remaining attachment screws. Tighten them as detailed above!

13 Refit the axis-3 motor.

See

Replacing motor axis 3 on page 354

.

14 Remove the lifting accessories.

15 Refit any cabling removed during the removal process.

16 Reconnect all connectors inside motors, axis 3 and 4. Refit the motor covers.

17 Perform a leakdown test.

Detailed in section

Performing a leakdown test on page 214 .

18 Refill the gearbox with oil.

Detailed in section

Changing oil, axis-

3 gearbox on page 176

.

19 Seal and paint the joints that have been opened.

See






4 Repair


Continued

20

Action

Re-calibrate the robot.

21

DANGER



.

Note








4 Repair

4.4.5 Replacement of complete lower arm

4.4.5 Replacement of complete lower arm

Location of lower arm

The lower arm is located as shown in the figure below.



.

xx0700000347

C

D

A

B

Lower arm

Pivot point, axis 2

Front shaft, balancing device

Attachment for lifting equipment, balancing device


Equipment, etc.

Art. no.

Lifting accessory, lower arm 3HAC027794-001

Rotation tool

Grease

Isopropanol

Standard toolkit -

3HAC17105-1

3HAB3537-1

11771012-208

Note

Tool that may be rented from ABB Robotics.

Used to rotate the motor pinion and gear if necessary, when brakes are released.

For lubrication of the shaft hole.

For cleaning of the shaft.







281

4 Repair


Continued

Equipment, etc.


Art. no.

Note





1

Action




Note











Removal, lower arm

The procedure below details how to remove the complete lower arm.

1

Action


Note

2

DANGER

Turn off all:








4 Repair


Continued

Action

3

CAUTION



.

Note

4

5

6

7

Remove the upper arm .

Disconnect and remove the cables from inside the lower arm.

Release any cable attachments.

Apply the shackle to the balancing device and raise to unload the weight of the device.

Detailed in section

Removal, upper arm on page 276 .

Detailed in section


.



.

Attachment is shown in the figure

Location of lower arm on page 281 .

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 333

Method 2 detailed in section

Unloading the balancing device using distance tool on page 327 .

8 Remove the securing screw from the balancing device front shaft.

Shown in the figure

Location of lower arm on page 281 .

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.

The figure shows IRB 6600 but the position of the lower arm shall be the same.

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!

xx0300000015



.

Detailed in section


.





4 Repair


Continued

Action

14 Raise the tool to unload the lower arm.

15 Remove the attachment screws and washers that attach the lower arm to the gearbox axis 2.

16 Lift the lower arm and place it on a secure surface.

Note

Refitting, lower arm

The procedure below details how to refit the lower arm.

Action Note

1

DANGER

Turn off all:




2

3



Fit two guideing pins in two opposite attachment holes of the lower arm.

xx0700000348

4 Apply the lifting tool to the lower arm.

5

CAUTION

The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly!



6 Lift the lower arm and move it to its mounting position.





4 Repair


Continued

7

Action Note

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.



8

9

Disconnect the power supply, if used.

Secure the lower arm with 18 of the 20 attachment screws and washers in gearbox, axis 2.

20 pcs: M16 x 50, tightening torque:

300 Nm.



before fitting.

10 Remove the guidings and secure the two remaining screws as detailed above!

11 Remove the lifting tool from the lower arm.

12 Refit and restore the balancing device.

See section

Replacing the balancing device (design 1) on page 302 .

13 Refit the upper arm.

14

15

Perform a leak-down test.

Refill the gearbox with oil.

See section

Refitting, upper arm on page 278

.

See section


.

See section


.

16 Refit and reconnect all cables inside the lower arm.

Resecure any cable attachments.

Detailed in section


.



18 Recalibrate the robot!









4 Repair


Continued

Action

19

DANGER



Note




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.

SMB unit DSQC633A with battery pack 3HAC16831-1 (with 2-pole battery contact) xx0700000121

A

B

C

D

SMB cover

Guide pins (2 pcs)

Battery cable (2-pole contact)

SMB unit DSQC633A





287

4 Repair


Continued

SMB unit RMU with battery pack 3HAC044075-001 (with 3-pole battery contact)


A xx1400002574

F

G

D

E

A

B

C

B C D

Battery pack (3-pole battery contact)

Battery holder RMU

Cover

Battery cable (3-pole battery contact)

Battery holder

Guide pins (2 pcs)

SMB unit RMU

E F G

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!





4 Repair


Continued

Equipment, etc.

SMB unit

Brush

Rust preventive

Standard toolkit

Circuit diagram

-

-

Article number

For spare part number, see:


-

3HAC026621-001

Note

Option: Foundry prime

Option: Foundry prime Equivalent:

• Mercasol



.

See chapter

Circuit diagrams on page 489 .

CAUTION



.

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:



3

CAUTION



Note

4


The unit is sensitive to ESD. Before handling the unit read the safety information in section


5 Remove the SMB cover by unscrewing its attachment screws.

Shown in the figure

Location of

SMB unit on page 287 .

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards which can result in hazardous failures.





4 Repair


Continued

6

7

8

9

Action Note

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 287 .

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

Refitting, SMB unit

Use this procedure to refit the SMB unit.

Action

1

DANGER

Turn off all:





3


Note



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 287 .

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.





4 Repair


Continued

8

Action

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.

Note

X9

X8

X10 xx1700000978

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


10 Seal and paint the joints that have been opened.

See


11 Update the revolution counter!

See

Updating revolution counters on page 444

.

12

DANGER



Replacement of SMB unit (Foundry Prime)

Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.

The repair must be done according to the previous repair procedure with the following additions.

Action Note

1

DANGER

Turn off all:



2 xx0200000023

WARNING







4 Repair


Continued

3

4

Action

Remove the SMB unit as detailed in

Removing, SMB unit on page 289

Note

Refit the new SMB unit according to step 3 - 6 in

Refitting, SMB unit on page 290

5

Note

Make sure that the gasket under the SMB cover is not damaged!

Secure the SMB cover with its attachment screws.

6

7

8

Apply rust preventive on the surface around the

SMB cover and under/on top of the screw heads.

Perform a leakdown test according to

Inspection of air hoses (Foundry Prime) on page 155

.

Update the revolution counter.

See


9

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.

xx0700000123

A

B

C

D

E

F

Brake release unit

Push button guard

Battery cover

Battery

SMB cover

Battery cable


Equipment, etc.

Brake release board

Standard toolkit


-


3HAC065020-

001

DSQC1050



.






4 Repair


Continued

Removing, brake release board

Use this procedure to remove the brake release board.

Action Note

1

DANGER

Turn off all:




2

CAUTION



.

3

ELECTROSTATIC DISCHARGE

(ESD)



4

5

6

Remove the push button guard from the SMB cover.

Shown in the figure

Location of brake release board on page 293

.

The guard must be removed to ensure a correct refitting of the brake release board.

Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board.

Disconnect the connectors X8, X9 and X10 from the brake release board.

X9

X8

X10

7 Remove the brake release board from the bracket by removing the four attachment screws.

xx1700000978

Location of the brake release unit is shown in the figure


.





4 Repair


Continued

Refitting, brake release board

Use this procedure to refit the brake release board.

1

Action



Note

2




3 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

5

6

4 Fasten the brake release board on the bracket with the attachment screws.

Make sure the board is positioned as straight as possible on the bracket! The push buttons can otherwise get jammed when the SMB cover is refitted.

Maximum tightening torque: 5 Nm.

Shown in the figure


.



.

Verify that the robot cabling is positioned correctly, according to previously taken picture/notes.

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.

7 Refit the SMB cover with its attachment screws.

8

WARNING

Before continuing any service work, follow the safety procedure in

The brake release buttons may be jammed after service work on page 221 .

Shown in the figure


.

9 Refit the push button guard to the SMB cover.

Shown in the figure


.

10 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.





4 Repair


Continued

Action



Note

12 If the battery has been disconnected the revolution counter must be updated.

Detailed in the Calibration chapter section


.

13

DANGER






4 Repair

4.5.3 Replacement of spherical roller bearing, balancing device

4.5.3 Replacement of spherical roller bearing, balancing device

Overview

There are some differences in the two designs of the robot IRB 6640, design 1 has:

• one ear on the lower arm as shown in the figure for design 1.

Design 2 has:

• two ears on the lower arm as shown in the figure for design 2

The difference is described in section

Design 1 and Design 2 of IRB 6640 on page 54 .

Location of bearing, Design 1

The bearings are located in the balancing device, as shown in the figure below.

xx0900000072





297

4 Repair


Continued

L

M

N

H

J

K

D

E

F

A

B

C

Washer

Sealing ring, radial (2 psc)


O-ring

Shaft


VK-cover

VK-cover


Cradle bearing kit

Hex socket head cap screw M16x70

Sealing washer

Location of bearing, Design 2

The bearings are located in the balancing device, as shown in the figure below.

xx0900000066





4 Repair


Continued

M

N

K

L

G

H

J

O

P

Q

D

E

F

A

B

C

Shaft

Washer


VK-cover

Washer

Radial sealing with dust lip 50x68x8



O-ring

End cover

Radial sealing (not used in clean room applications)

Cradle bearing kit


Washer


VK-cover


Equipment


Grease

Toolkit

Other tools and procedures may be required.

See references to these procedures in the step-by-step instructions below.

Spare part no.

See Spare parts

Art. no.

3HAB3537-1

3HAC028920-001

Note

Includes the parts shown in the figure above.

For lubrication of the components.

The tools in the set are shown in the section

Dismounting and mounting tool 3HAC028920-001 on page 469


Tool set up 3HAC028920-001

The set up of the press tool used for the process of removal and refitting of spherical bearing is described in section

Dismounting and mounting tool 3HAC028920-001 on page 469 .





299

4 Repair


Continued

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:




2

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling parts.

See


3

4

5

Remove the balancing device from the robot.

Detailed in section


or in

Replacing balancing device (design 2) on page 311 .

Remove the both sealing spacers with a screwdriver or any equal tool.

Remove the sperical roller bearing, using the dismounting and mounting tool

3HAC028920-001.

Shown in the figure

Location of bearing,

Design 1 on page 297

and

Location of bearing, Design 2 on page 298

Described in section

Removal front bearing Design 1 on page 475

or


.

Refitting, spherical roller bearing

Use this procedure to refit the spherical roller bearing to the balancing device front ear.

Action Note

1

DANGER

Turn off all:




2

3



Grease the inside walls of the front ear.





4 Repair


Continued

4

Action

Press in the sealing washer and the sealing.

Note xx0900000115

5

6

7

8

9

Refit the new bearing and sealings.

Apply grease to the new sealing rings and o-rings and fit them.

Sealing and o-ring are showed in the figure


and

Location of bearing, Design

2 on page 298

.

Refit the end cover.


Refitting front bearing and sealing Design 1 on page 477

or in

Refitting front bearing with sealing Design

2 on page 480

.

Refit the balancing device to the robot.

End cover shown in figure


or

Location of bearing, Design 2 on page 298 .

Detailed in section


or

Replacing balancing device (design 2) on page 311

.

Lubricate the spherical roller bearing in the ear.

Detailed in section

Lubrication of spherical roller bearing, balancing device on page 194

Note

The balancing device must be mounted on the robot when lubrication is performed!

10 Make sure no incorrect leakage occurs. It could indicate damaged o-rings.



12

DANGER



.



.




301

4 Repair

4.5.4.1 Replacing the balancing device (design 1)

4.5.4 Replacement of balancing device

4.5.4.1 Replacing the balancing device (design 1)

Introduction

This section describes how to replace balancing device (design 1).

Replacement of design 2 of the balancing device is described in

Replacing balancing device (design 2) on page 311

.

Location of balancing device

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

xx0800000477

A

B

C

Balancing device

Cradle bearing



Equipment

Balancing device

Spare part no.

See Spare parts chapter

Art. no.


302

Note




4 Repair


Continued

Equipment

Mainteance parts, shaft

Mainteance parts, cradle

Locking screw

Spare part no.



Art. no.

Bearing grease

Grease

Grease pump


Shackle

Press tool, balancing device

Distance tool

Dismantle and mounting tool

Hydraulic cylinder

3HAC030662-001

3HAC028920-001

3HAC11731-1

Note

3HAC15556-1

3HAC020997-001

3HAC020902-001


For securing the lower arm.

3HAB3537-1

-

3HAC042534-001

To lubricate spherical roller bearing.

For unloading and restoring the balancing device.

Hydraulic pump,

80 MPa

Standard toolkit.

Brush

Rust preventive

Loctite 577

Sikaflex 521FC

-

3HAC13086-1

3HAC034903-001

12340011-116

3HAC026759-001

For dismantling and mounting of shaft and bearings.

To be used with these tools:

• 3HAC028920-001

• 3HAC020902-001

To be used with the hydraulic cylinder 3HAC11731-1.



.

Option: Foundry Prime


Equivalent:

• Mercasol



CAUTION



.

Removing balancing device (design 1)

Use this procedure to remove balancing device, design 1.

Action Information

1

CAUTION


See






4 Repair


Continued

2

3

Action

Remove all equipment if any, on or close to the balancing device.

Fit the lifting tool with shackle to the balancing device and raise to unload the device.

Information

CAUTION

The balancing device weighs 210 kg! All lifting equipment used must be sized accordingly!

4 Secure the lower arm using a lifting sling or using the locking screw in the frame.

xx0900000092

5 xx0800000249

• A: Locking screw

Use one of the methods to unload the balancing device in order to make the piston rod and front ear adjustable when pulling the shaft out:

• Method 1 : Unload the balancing device with the press tool .

• Method 2 : Unload the balancing device with the distance tool .

For art. no. see:

•


The methods are described in sections:

• Method 1:


• Method 2:

Unloading the balancing device using distance tool on page 327

6

DANGER

Turn off all:







4 Repair


Continued

7

Action

Remove the VK cover in order to reach the shaft.

Information

Tip

Hit the VK cover gently at the bottom part of it with a plastic hammer or similar and tilt it out.

8

9

Remove the retaining ring bore .

Remove the front shaft using the dismantle and mounting tool .

For art. no. see:

•


How to use the tool, see:

•

Dismounting and mounting tool

3HAC028920-001 on page 469

10 Remove the VK cover in order to reach the shaft holding the balancing device.

Tip

Hit the VK cover gently at the bottom part of it with a plastic hammer or similar and tilt it out.

11

12

13

Wipe off all residual grease inside the hole.

Remove the hex socket head cap screw

(M16x70) securing the piston rod shaft.

Remove the retaining ring bore securing the shaft.

xx0900000095 xx0900000079

• A: Retaining ring bore





4 Repair


Continued

14


Remove both the cradle bearings and the balancing device shafts using the dismantle and mounting tool .

For art. no. see:

•


xx0900000074

15

16

Perform this procedure of pulling out the shafts on both sides of the cradle.

Lift the balancing device gently backwards to a secure area.

Refitting balancing device (design 1), standard

Use this procedure to refit balancing device (design 1) on a standard robot.

1

2

Action



Information

Fit the shackle to the balancing device.

For art. no. see:

•


3

CAUTION


4

5

Refit one of the two retaining ring bore .

Grease the cradle.

xx0900000094





4 Repair


Continued

6


Refit the cradle bearings and the balancing device shafts with the dismantle and mounting tool .

For art. no. see:

•


How to use the tool see:

•


3HAC028920-001 on page 469

7

8

9

Perform this on the side where the retaining ring bore is mounted:

• Refit the cradle bearings and the balancing device shafts to the retaining ring bore .

Perform this on the side where the retaining ring bore is not mounted:

• Refit the cradle bearings and balancing device shafts completely .

It should look like this. See figure!

xx0900000060

10 Use Loctite 577 on the threads on the balancing device.

xx0900000083

• A: Shows a correct fitting

CAUTION

Do not use Loctite on the threads of the hex socket head cap screw M16x70.

xx0900000088

• A: Loctite 577





4 Repair


Continued

11

12

13

14

15

Action

Perform the following procedure of refitting the shafts on both sides of the cradle before refitting of the shaft at the piston rod shaft front eye.

Lift the balancing device to the back of the robot.

Information

Fit the balancing device on the side where the shaft is in final position and fix it lightly using the hex socket head cap screw

M16x70.


On the other side, use the hex socket head cap screw M16x70 to refit the cradle bearings and the balancing device shafts to the final position.


Lock the cradle bearings with the retaining ring bore .

xx0900000089

16

17

18

19

Fit new VK covers on both sides.

Raise the balancing device to a position where the shafts shall be fitted.

Lubricate the shaft with grease .

Amount: 40 ml.

Refit the front shaft using the dismantle and mounting tool.

For art. no. see:

•


20

21

22

23

24

25

Secure the shaft with its attachment screw .



Refit the retaining ring bore.

Refit the VK cover.

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.

Amount: 20 ml.

Restore the balancing device depending on which method used.

• Method 1:

Restoring the balancing device using a hydraulic press tool on page 336

• Method 2:

Restoring the balancing device using distance tool on page 331







4 Repair


Continued

Refitting balancing device (design 1), Foundry Prime

Use this procedure to refit balancing device (design 1) on a Foundry Prime robot.

Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.

The repair must be done according to the previous repair procedures with the following additions when refitting the balancing device.


1

DANGER

Turn off all:



2 Apply Mercasol to the shafts and holes.

For art. no. see:

•


xx0700000452

For a cut away view, see below.

xx0700000453

• A: Mercasol - surface on the balancing device

• B: Mercasol - on hole in the shaft

• C: Mercasol - on shaft.





309

4 Repair


Continued

3

Action

Apply Mercasol on these machined surfaces of the balancing device:

• holes in the lower arm ear

• holes in the rod bracket

• shaft.

Information

4

DANGER



.

xx0700000454

• A: Machined surfaces in lower arm ear

• B: Machined surfaces in rod bracket

• C: Machined surfaces on shaft.




4 Repair

4.5.4.2 Replacing balancing device (design 2)

4.5.4.2 Replacing balancing device (design 2)

Introduction

This section describes how to replace balancing device (design 2).

Replacement of design 1 of the balancing device is described in


.

Location of balancing device

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

xx0900000075

A

B

C

Balancing device

Cradle bearing






311

4 Repair


Continued

Location of parts in maintenance sets, cradle and shaft

The figure shows the maintenance sets for the cradle and for the shaft.

L

M


312

D

E

F

A

B

C

J

K

G

H xx0900000066

Maintenance set - Shaft

Shaft

Washer, M16x70 quality 8.8 steel

Hex socket head cap screw M16x70 quality 8.8 steel

VK-cover

Washer




O-ring

End cover

Maintenance set - Cradle

Radial sealing (Not used in Clean Room applications)

Cradle bearing kit




4 Repair


Continued

P

Q

N

O


Washer, M16x70 quality 8.8 steel


VK-cover

Required parts

Equipment

Balancing device



Front shaft

VK cover

Art. no.

See chapter:

• Spare parts

Note

See chapter:

• Spare parts

For content see the figure in :

•

Location of parts in maintenance sets, cradle and shaft on page 312

See chapter:

• Spare parts

For content see the figure in:

•


3HAC037916-001

3HAA2166-12


Equipment

Loctite 2701

Loctite 577

Locking screw

Bearing grease

Grease

Grease pump


Shackle


Distance tool

Dismantle and mounting tool

Hydraulic cylinder

Hydraulic pump,

80 MPa

-

Art. no.

Note

Used to lock the screw that hold the shaft in the front ear.

-

12691907-001

M16x60 quality 12.9 Gleitmo.

For securing of the lower arm.

3HAB3537-1

-

3HAC042534-001

3HAC15556-1

3HAC020997-001

3HAC020902-001 For unloading and restoring the balancing device, (Method 1).

3HAC030662-001

3HAC028920-001

For unloading and restoring the balancing device, (Method 2).

For dismantling and mounting of shaft and bearings.

3HAC11731-1

3HAC13086-1

To be used with these tools:

• 3HAC028920-001

• 3HAC020902-001

To be used with the hydraulic cylinder

3HAC11731-1.





313

4 Repair


Continued

Equipment


Standard toolkit -

-

Art. no.

Note




.


Equipment

Rust preventive

Sikaflex 521FC

Loctite 577

Brush

Art. no.

Note

3HAC034903-001 Mercasol

3HAC026759-001

-

12691907-001

CAUTION



Removing balancing device, (design 2)

Use this procedure to remove the balancing device (design 2).

Action Note

1

CAUTION



2 Remove all equipment, if any, on or close to the balancing device.





4 Repair


Continued

3

Action

Fit the lifting tool to the balancing device and raise to unload the weight.

Note

For art. no. see:

•

Required equipment - tools etc. on page 313

CAUTION


xx0900000092

4 Secure the lower arm using a lifting sling or using the locking screw in the frame.

For art. no. see:

•


xx0800000249

• A: Locking screw





315

4 Repair


Continued

5

Action Note

Foundry Prime robots:

Cut the paint layer with a knife in the joint between the rear cover and the balancing housing and remove the cover.

The figure shows the principal method.

Note

Keep the cover for the refitting.

xx0900000121

6

7

8 xx1000000554

• A: Joint between rear cover and balancing housing

Unload the balancing device in order to make the ear of the piston rod adjustable when pulling the front shaft out.

Use one of the two methods described.

Method 1 : The press tool must be used if the balancing device shall be replaced with a new one.

Method 2 : The distance tool can be used:

• when the front shaft is replaced

• when the spherical bearing at the front shaft is replaced

• during service work on axis 2.

Method 1:

Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out.



Method 2:

Unload the balancing device with the distance tool in order to make the piston rod and front ear adjustable when pulling the shaft out.



9

DANGER

Turn off all:







4 Repair


Continued

10

Action Note

Remove the protection plug covering the shaft in the center of the front eye of the piston rod shaft.

Cleanroom robots:

Note

The protection plug used in Cleanroom applications must also be refitted after the refitting of the balancing device!

Do not loose it!

11

12

Remove the hex socket head cap screw M16x70 securing the front eye of the piston rod shaft.

Remove the front shaft using the dismantle and mounting tool .

For art. no. see:

•


See section:


3HAC028920-001 on page 469

.

13 xx0900000080

• A: Protection plug

• B: Hex socket head cap screw M16x70

• C: Washer

• D: Front shaft

• E: Press tool or Distance tool

Remove the VK cover in order to reach the shafts holding the balancing device. Hit the VK-cover at the bottom part of it with a hammer or similar and tilt it out

Note

It is almost impossible to remove the VK-cover without damage. New VK-covers are needed.

14 Remove the hex socket head cap screw M16x70 securing the shaft.

See the figure in:

•


15 Wipe off all residual grease inside the hole.





317

4 Repair


Continued

16

Action

Remove the retaining ring, bore securing the shaft and bearing.

Note

17 xx0900000079

• A: Retaining ring, bore

Remove both rear shaft units using the dismounting and mounting tool .

For art. no. see:

•


For tool configuration see section:

Removal rear shafts Design 1 and

2 on page 481

Note

Make sure that the M16 threads in the rear shaft are clean before fitting the tool!

xx0900000074

18 Remove the balancing device.

Preparation of the spare part

Use this procedure for the preparation of the spare part.

1

Action

Remove the transport protection at the location of the rear shafts.

Note xx1000000627

• A: Transport protection





4 Repair


Continued

2

Action

Apply rust protection (Mercasol) on the machined surface.

Note

For art. no. see:

•


Prime on page 314

3 Apply rust protection (Mercasol) on the machined surfaces of the piston rod ear.

xx1000000628

• A: Mercasol

For art. no. see:

•


Prime on page 314

4 Cut the paint with a knife in the joint between the rear cover and the balancing unit housing .

xx1000000629

• A: Mercasol


5 Remove the cover with the air nipple.

xx0900000121

Note

Keep the cover for refitting on the new balancing unit.





319

4 Repair


Continued

6

Action Note

Fit the press tool, balancing device and unload the balancing device.

See section

•


For art. no. see:

•


xx1000000630

• A: Press tool, balancing device

Refitting balancing device, Design 2

Use this procedure to refit the balancing device, design 2.

1

2

3

4

Action

Clean the joints that have been opened.

See


Note

Clean the machined holes in the cradle and lubricate with grease.

Refit one of the two retaining rings .

Use new parts (maintenance parts cradle).

Use the dismantle and mounting tool and refit new rear shaft units in both locations.

Note

Adjust the shaft unit in order to get one of the lubrication holes in the bearing facing downwards in the cradle!

For art. no. see:

•


How to use the tool, see section:

Dismounting and mounting tool 3HAC028920-001 on page 469

.

xx0900000061

• A: Lubrication hole facing down

• B: Cradle





4 Repair


Continued

5

Action

On the side where the retaining ring, bore is fitted, the rear shaft unit shall be pressed against the retaining ring, bore.

Note

6 On the side where the retaining ring, bore is not fitted, refit the rear shaft unit completely into the frame.

xx0900000084

• A: Rear shaft unit

• B: Retaining ring, bore

7 The rear shaft unit to the right shows a correct fitting.

xx0900000085 xx0900000083





321

4 Repair


Continued

8

Action Note


Apply rust preventive (Mercasol) on the shaft journals and on the unpainted surfaces in the holes.

For art. no. see:

•


Prime on page 314

Note

Use a thin layer of Mercasol 3106 on the surface for the position of the sealing ring .

9 Fit new radial sealings on both shafts.

Note

The radial sealings are not used in

Cleanroom applications.

xx1000000558

• A: Surfaces where Mercasol is applied

• B: Sealing ring xx0900000093

10 Fit the lifting tool to the balancing device.

For art. no. see:

•



322 xx0900000094

CAUTION





4 Repair


Continued

11

Action

Use Loctite 577 on the threads in the balancing device in order to seal the hole.

Note

Note

This procedure eliminates the risk to get

Loctite in the M20 threads on the shaft end. The M20 thread is used by the dismantling tool.

12

13

14

15

16

Perform the following procedure of refitting the shafts on both sides of the cradle before refitting of the shaft at the piston rod shaft front eye.

Lift the balancing device in to the cradle.

Fit the balancing device on the side where the shaft is in final position and fix it lightly using the hex socket head cap screw

M16x70 quality 8.8 steel.

On the other side, use the hex socket head cap screw M16x70 quality 8.8 steel, to refit the rear shaft unit to its final position.

Lock the shaft unit by fitting the retaining ring, bore.

xx0900000088

• A: Loctite 577

17

18

Secure both M16x70 screws.

Fit new VK- covers on both sides.

xx0900000089






323

4 Repair


Continued

19

Action

Apply rust preventive (Mercasol) on the front shaft.

Note

For art. no. see:

•


Prime on page 314

20 xx1000000559

• A: Mercasol

Refit the front shaft using the dismantle and mounting tool .

Note

For art. no. see:

•



Dismounting and mounting tool 3HAC028920-001 on page469 .

• Apply rust preventive (Mercasol) on the shaft.

21

22 xx0900000080

• A: Protection plug

• B: Hex socket head cap screw

M16x70

• C: Washer

• D: Shaft

• E: Press tool or Distance tool


Refit the hex socket head cap screw

M16x70 quality 8.8 steel.

Use Loctite 2701 .

Restore the balancing device in one of the methods.

Method 1: Described in section

Restoring the balancing device using a hydraulic press tool on page 336

Method 2: Described in section

Restoring the balancing device using distance tool on page 331

.





4 Repair


Continued

23

Action Note

Apply Loctite 577 in the attachment holes of the cover.

For art. no. see:

•


Prime on page 314

24

25

26 xx1000000631

• A: Loctite 577 in holes (4 pcs)

If the balancing device is reused, check that the gasket on the cover is not damaged.

Fit the old cover with the air nipple

Apply rust preventive (Mercasol) around the edge of the cover as a protection of the broken paint layers.

For art. no. see:

•


Prime on page 314

27 Fill the cradle bearings with 70 ml, Optimol

PDO.

xx1000000632

• A: Mercasol

Note

The inner hole is used for lubrication.

The outer hole is used for air outlet.

xx0900000090





325

4 Repair


Continued

28

Action

Fill the spherical roller bearing at the front shaft with 20 ml, Optimol PDO.

Note

Note

Open the ventilation screw M6 at the opposite side of the link ear.

Refit the M6 screw with sealing washers.



xx0900000102




4 Repair

4.5.4.3 Unloading the balancing device using distance tool

4.5.4.3 Unloading the balancing device using distance tool

Overview

This section details how to unload the balancing device using a distance tool

3HAC030662-001. This method is used when the balancing device is reusable.

DANGER

There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property.

DANGER

Do not remove the distance tool from a dismounted balancing device.





327

4 Repair


Continued

Distance tool xx0800000478

A Distance tool 3HAC030662-001





4 Repair


Continued

Unloading procedure

1

Action

Jog the robot lower arm to a maximal forward position.


2 Remove the cover plate on the back of the balancing device.

CAUTION


See


xx0800000479





329

4 Repair


Continued

3

Action

Fit the distance tool on the back of the balancing device using the four screws.


A

4 Jog the robot lower arm backward to calibration position (0°).

xx0800000480

• A . Distance tool

330 xx0800000481




4 Repair

4.5.4.4 Restoring the balancing device using distance tool

4.5.4.4 Restoring the balancing device using distance tool

DANGER


DANGER

Do not remove the distance tool 3HAC030662-001 from a dismounted balancing device.


Equipment

End Cover Gasket

Distance tool

Spare part no.

See Spare parts

Art. no.

3HAC030662-001

Note

To be replaced if damaged!

For unloading and restoring the balancing device, (Method 2)

Standard toolkit

Loctite 577

Sikaflex 521FC

CAUTION



.





331

4 Repair

4.5.4.4 Restoring the balancing device using distance tool

Continued

Restoring procedure

1

Action

Jog the lower arm forward to release the pressure from the distance tool.

Note/Illustration xx0800000482

2

3

4

Remove the distance tool.

Fit a new end cover gasket if needed.

Fit the cover on the back of the cylinder with the four screws.

Apply Sikaflex 521FC on the end cover gasket.

332

5 Use Loctite 577 on the four screws.

xx0900000104

Tightening torque 47Nm




4 Repair

4.5.4.5 Unloading the balancing device using hydraulic press tool

4.5.4.5 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


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





333

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

Hydraulic pump, 80 MPa

Standard toolkit -

Art. no.

3HAC020902-001

3HAC11731-1

3HAC13086-1

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.

To be used with the hydraulic cylinder.



.

CAUTION



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 Press device

Art. no: 3HAC18100-1 xx0300000599 xx0700000475





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 336 .

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 334 .

The moving pin is shown in the figure

Press tool and hydraulic cylinder on page 333 .

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 333 .

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

8 xx0700000422

• E: Rear cover attachment screws,

4 pcs

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 333

.

Fit the hydraulic cylinder to the press tool.



.

See the figure


.

Connect the hydraulic pump to the cylinder.



.

Increase the pressure and press until the marking on the moving pin indicates the correct position (in level with the pressure block).

See the figure


.

Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.

Turn the fix plate to position "Closed" in order to lock the tool in loaded condition.

See the figure


.

9 Unload the hydraulic cylinder.

10 The hydraulic cylinder may now be removed from the tool, when necessary.




335

4 Repair

4.5.4.6 Restoring the balancing device using a hydraulic press tool

4.5.4.6 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


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


336

Press block

Hydraulic cylinder

Press device

Bolt, press device

Moving pin with marking




4 Repair


Continued

F

G

Bolt (4 pcs)

Pin, attached to the fix plate


Equipment, etc.

Hydraulic cylinder


Brush

Rust preventive

Locking liquid -

Art. no.

3HAC11731-1

3HAC13086-1

-

3HAC026621-001

Standard toolkit

Sikaflex 521FC

3HAC15571-1

Note

To be used with press tool.

To be used with hydraulic cylinder.

Equivalent:

• Mercasol

Loctite 577

Used to secure the attachment screws of the rear cover at the end of the balancing device.



CAUTION



.

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

Action Note

Refit the hydraulic cylinder to the press tool, in case it has been removed.

Shown in the figure


.

Press with the cylinder and the hydraulic pump until the fix plate is movable again. Turn the pin on the fix plate to position "Open".

Shown in the figure


!

Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.

Unload the hydraulic cylinder and make sure the moving pin indicates that the tool has returned to its starting position.

Shown in the figure


!

Remove the hydraulic cylinder.

Remove the press tool by unscrewing the bolts.

Shown in the figure


!

Refit the gasket to the rear of the balancing device.





337

4 Repair


Continued

7

Action

Refit the rear cover to the balancing device with its attachment screws, using locking liquid. Apply sikaflex 521FX on the cover.

Note

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!

xx0700000422

• E: 4 pcs: M10x30, tightening torque: 50 Nm.

Locking liquid is specified in


.




4 Repair

4.6.1 Replacing motor axis 1

4.6 Motors

4.6.1 Replacing motor axis 1

Note

This procedure requires calibration of the robot.

Use the Calibration Pendulum tool 3HAC15716-1.

Introduction

This section describes how to replace motor axis 1.

The section consists of these parts:

•

Removing motor axis 1 on page 341

•

Preparation of the frame before fitting the new motor axis 1 on page 342

•

Refitting motor axis 1 on page 343

•

Connecting motor axis 1 on page 344

•

Refitting the concluding parts on page 345

Location of motor axis 1

The motor axis 1 is located as shown in the figure.

xx0700000085

A Motor, axis 1

Required parts

Part

Motor axis 1

Spare part no.

See chapter:

• Spare parts




Note

Includes:

• motor

• pinion

• o-ring


339

4 Repair


Continued

Part

O-ring

Gasket

Spare part no.

21522012-430

3HAC3438-1

Note

Must be replaced when refitting the motor.

Must be replaced when reassembling the motor.


Equipment Art. no.

Grease

Removal tool motor

M12x

Lifting tool, motor axis 1, 4 , 5

3HAB3537-1

3HAC14631-1

Power supply

3HAC14459-1

Extension 300 mm for bits 1/2" 3HAC12342-1

-

Note

Used to lubricate the o-ring.

Always use removal tools in pairs!

Standard toolkit -

Calibration Pendulum toolkit 3HAC15716-1


Circuit diagram See Circuit diagram .


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush

24 VDC, max. 1.5 A




.

Complete kit which also includes user manual.


Art. no.

3HAC034903-001

3HAC026759-001

-

12340011-116

Note

Mercasol

CAUTION







4 Repair


Continued

Removing motor axis 1

Use this procedure to remove motor axis 1.


1

DANGER

Turn off all:



2

CAUTION


See


3 Cut the paint with a knife in the joint between the motor and the structure in order to avoid that the paint cracks.


xx0900000121

4 Remove the cover for connector access on top of the motor.

The figure shows a Foundry Prime motor.

B

A

C

D xx0600002874

Parts:

• A: Attachment screws (4 pcs)

• B: Air hose (only Foundry Prime)

• C: Cover

• D: Motor





4 Repair


Continued

5

Action


Note

Keep the old cover, with the air nipple fitted.

6 Remove the cable gland cover at the cable exit on the motor.

Information

7

8

9 xx0200000199

Part:

• A: (Position of) Cable gland cover

Disconnect all connectors in motor axis 1.

Apply the the motor.

lifting tool, motor axes 1, 4, 5 to For art. no. see:

•


To release the brakes, connect the 24 VDC power supply.

Connect to connector R2.MP1:

• + = pin 2

• - = pin 5

See section

•


10

CAUTION

The motor weighs 25 kg! All lifting equipment used must be sized accordingly!

11 Unscrew the attachment screws and washers of the motor and lift it in order to get the pinion away from the gear.

See the figure in:

•

Location of motor axis 1 on page 339

12

13

Disconnect the 24 VDC power supply.

Remove the motor by carefully lifting it straight up.

Preparation of the frame before fitting the new motor axis 1

Use this procedure for the preparation of the frame before refitting motor axis 1.

1

2

Action

Grind the paint on the surface carefully to get a smoth surface.

Clean the surface from contamination such as oil and dirt.

Note





4 Repair


Continued

3

Action Note

Apply Loctite 574 on the surface as shown in the figure.

For art. no. see:

•


Prime on page 340

xx1000000560

Part:

• A: Loctite 574

Refitting motor axis 1

Use this procedure to refit motor axis 1.

Action

1

DANGER

Turn off all:



Note

2 Make sure the o-ring on the circumference of the motor is seated properly.

Lubricate the o-ring with some grease.

For art. no. see:

•


3

CAUTION


4

5

Apply the lifting tool, motor axes 1, 4, 5 to the motor.

For art. no. see:

•


In order to release the brakes, connect the

24 VDC power supply.


• + = pin 2

• - = pin 5

See section

•






4 Repair


Continued

6

7

8

Action

Lower the motor into position, making sure that:

• the motor pinion is properly mated to the gear of gearbox of axis 1

• the motor pinion does not get damaged

• the motor is turned the correct way as shown in the figure in


.

Note

Secure the motor with its attachment screws and washers.

Tightening torque: 50 NM.

M10x40

4 pcs


Connecting motor axis 1

Use this procedure to connect motor axis 1.

1

Action

Fit a new gasket on the cable gland.

Note

For art. no. see:

•


2

3

4 xx0200000199

Part:

• A: (Position of) Cable cland cover.

Reconnect all connectors of motor axis 1.

Connect in accordance with markings on connectors.

Refit the cable gland cover at the cable exit with its attachment screws.

Make sure the cover is tightly sealed.

Refit the motor cover with its attachment screws.






4 Repair


Continued

Refitting the concluding parts

Use this procedure to refit the concluding parts.

1

Action

After fitting motor axis 1 on the robot, the surface between motor and base must be protected with rust preventive (Mercasol) .

Note

For art. no. see:

•


Prime on page 340

2

3

4 xx0600002877

Parts:

• A: Mercasol on surface between motor and base

• B: Motor axis 1

Clean and paint the joints that have been opened. See


Perform an air leak test.

Recalibrate the robot.

See section

•

Inspection of air hoses (Foundry

Prime) on page 155




.

5

DANGER



.




345

4 Repair



Introduction



•


•

Preparation of the frame before fitting a new motor on page 350

•


•


•



The motor axis 2 is located on the left-hand side of the robot as shown in the figure.

xx0700000086

A Motor axis 2

Required parts

Equipment

Motor axis 2

O-ring


346

Spare part no.

See chapter:

• Spare parts

21522012-430

Note

Includes:

• motor

• pinion

• o-ring





4 Repair


Continued

Equipment

Gasket

Spare part no.

3HAC3438-1

Note

Must be replaced if the cabling is dismantled from the motor.


Equipment

Grease

Locking screw

Removal tool, motor M12x

Guide pins

Art. no.

3HAB3537-1

3HAA1001-266

3HAC14631-1

3HAC15521-2

Note

For lubricating the o-ring.

M16x60

For securing the lower arm.

Always use the removal tools in pairs.

M10x150

For guiding the motor.

Always use guide pins in pairs.

Lifting tool, motor axes 2,

3, 4

3HAC026061-001

Extension bar for bits 1/2" 3HAC12342-1

Power supply -

Rotation tool

Standard toolkit

Calibration Pendulum toolkit


Circuit diagram

-

3HAC17105-1

3HAC15716-1

See Circuit diagram .

300 mm

24 VDC, max. 1.5 A


Used to rotate the motor pinion when mating it to the gear when brakes are released with the 24 VDC power supply.






Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush

Art. no.

3HAC034903-001

3HAC026759-001

-

12340011-116

Note

Mercasol

CAUTION



.





4 Repair


Continued



1

Action

Move the robot to a position close to its calibration position to allow the lock screw to be inserted into the hole for lock screw.

Information xx0800000249

Part:

• A: Lock screw

2

DANGER

Turn off all:



3

CAUTION


See


4

5

Lock the lower arm in position by inserting the lock screw into the hole and securing it.

See the figure above!

For art. no. and dimension see:

•


Drain the oil from gearbox axis 2.

See section

•






4 Repair


Continued

6

Action

Cut the paint layer with a knife in the joint between the motor and the structure to avoid that the paint cracks.

Information


xx0900000121

7

8

Cut the paint layer with a knife in the joint between the cover and the motor housing to avoid the paint layer to crack.

See figure below!

Remove the cover of the motor for connector access.


B

A

C

D xx0600002874

Parts:

• A: Attachment screws


• C: Cover

• D: Motor

9

Note

Keep the old cover with the air nipple fitted.

10

11

Remove the cable gland cover at the cable exit.

Make sure the gasket is not damaged.

Disconnect all connectors on motor axis 2.





349

4 Repair


Continued

12

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!

Information

Use the lock screw to lock the lower arm as described above.

13

14

15

To release the brake, connect the 24 VDC power supply.


• + = pin 2

• - = pin 5

See section

•


Remove the attachment screws securing motor axis 2.

Fit guide pins in two of the attachment holes for the motor, opposite each other.

For article number see:

•


16

17

18

19

If required, press the motor out of position by fitting the removal tool, motor to the remaining attachment holes for the motor.


•


Always use the removal tool in pairs.

Remove the removal tool motor and fit the lifting tool motor axes 2, 3, 4 to the motor.


•


Remove the motor by carefully lifting it straight up, making sure the motor pinion does not get damaged.


Preparation of the frame before fitting a new motor

Use this procedure for the preparation of the frame before fitting motor axis 2.

1

2

Action

Grind the paint edge on the surface carefully to get a smooth surface.

Note






4 Repair


Continued

3

Action Note



•


Prime on page 347

xx1000000561

Part:

• A: Loctite 574



Action

1

DANGER

Turn off all:



Note

2

3

4

5

6



Make sure the o-ring on the circumference of the motor is seated properly.



•




• + = pin 2

• - = pin 5

Fit the lifting tool axes 2, 3, 4 to the motor.

See section

•



•

Required equipment - tools etc.

on page 347

Fit two guide pins in the lower motor attachment holes.


•


on page 347





351

4 Repair


Continued

7

8

9

Action

Lift the motor and put it on the guide pins as close as possible without pushing the motor pinion into the gear.

Make sure that the motor is turned the right way - that is with cables facing downwards.

Note

Remove the lifting tool and allow the motor to rest on the guide pins.

Use the rotation tool in order to rotate the motor pinion when mating it into the gear.

When the motor is pushed in position make sure the motor pinion is properly mated to the gear of the gearbox.

Be careful not to damage gears in the process.


•


on page 347

xx0200000165

Part:

• A: Rotation tool

10

11

Remove the guide pins.

Secure the motor with its attachment screws and plain washers .


M10x40

4 pcs

Reused screws can be used providing they are lubricated as described in section

Screw joints on page 461 before

fitting.

12 Disconnect the 24 VDC power supply.


Use this procedure to connect all connectors on motor axis 2.

1

2

3

4

5

Action

Install a new gasket in the cable gland.

Note


•


Connect all connectors on motor axis 2.

Connect in accordance with the markings on connectors.

Refit the cable gland cover at the cable exit.

Refit the cover of the motor with its attachment screws.


Apply rust protection (Mercasol) on the frame, outside the motor flange as a protection of the broken paint layers.





4 Repair


Continued


Use this procedure to refit the concluding parts on.

Note

1

2

Action

Remove the lock screw used to secure the lower arm.

Perform a leak-down test .

3 Refill the gearbox with oil .

See section

•


See section

•


4

5







6

DANGER






353

4 Repair



Introduction



•


•

Preparation of the upper arm housing before fitting motor axis 3 on page 358

•


•


•



The motor axis 3 is located on the left hand side of the robot as shown in the figure.

xx0200000186

A

B

C

Motor axis 3

Cable gland cover, motor axis 3


Required parts

Equipment

Motor

O-ring

Gasket


354

Spare part no.

See chapter:

• Spare parts

21522012-430

Note

Includes:

• motor

• pinion

• o-ring

Must be replaced when reassembling motor.

3HAC3438-1




4 Repair


Continued


Equipment

Grease


Lifting tool motor 2-3


Attachment screws

Washers

Guide pins

Guide pins

Extension for bits 1/2"

Rotation tool

Power supply

Standard toolkit


-

-

Art. no.

3HAB3537-1

3HAC14631-1

3HAC026061-001

3HAC12708-1

3HAB3409-86

Note


Always use removal tools in pairs.

3HAA1001-186

3HAC15521-1

3HAC15521-2

3HAC12342-1

3HAC17105-1

3HAC15716-1



Used to fix axis 3.

M16x60

For mechanical stop axis 3.

For mechanical stop axis 3.

M10x100


M10x150


300 mm


24 VDC max 1.5 A




.




Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol

CAUTION



.





355

4 Repair


Continued



1

2

Action


Information

See section

•


Unload the upper arm using one of these methods:

• 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 as shown in the figure. Tightening torque: 115

Nm.

xx0300000051

Part:

• A: Third and final attachment hole for fitting the mechanical stop

• B: Fixed stop

3

DANGER

Turn off all:



4

CAUTION


See


5

6

Remove any equipment hindering access to motor axis 3.

Cut the paint with a knife in the joint between the motor and the structure in order to avoid that the paint cracks.

Figure showing the principal method: xx0900000121





4 Repair


Continued

7

8

Action

Cut the paint layer with a knife in the joint between the cover and the motor housing to avoid the paint layer to crack.

See the figure below!

Information

Remove the cover for connector access on the motor.

Figure shows Foundry Prime motor.

B

A

C

D xx0600002874

Parts:

• A: Attachment screws


• C: Cover

• D: Motor axis 3

9

Note

Keep the old cover, with the air nipple fitted.

10

11

12

13

Remove the cable gland cover at the cable exit.

See the figure in:

•


Make sure the gasket is not damaged!


To release the brakes, connect the 24 VDC power supply .

See section

•



• + = pin 2

• - = pin 5

Unscrew the attachment screws securing the motor.

See the figure in:

•


14

15

16

Fit guide pins in the screw holes for the attachment screws.

For art. no. see:

•


Press the motor out of position by fitting the removal tool, motor in the remaining attachment holes for the motor.

For art. no. see:

•



Apply the lifting tool, motor axes 2-3 to the motor.

For art. no. see:

•






4 Repair


Continued

Action

17

CAUTION


Information

18

19

20

Lift the motor in order to get the motor away from the gear.

Remove the motor by carefully lifting it straight out.

Make sure the motor pinion is not damaged.


Preparation of the upper arm housing before fitting motor axis 3

Use this procedure for the preparation of the upper arm housing before refitting motor axis 3.

1

2

3

Action


Note




•


Prime on page 355

xx1000000562

Part:

• A: Loctite 574





4 Repair


Continued



Action

1

DANGER

Turn off all:



Note

2

3

4

5






•


Fit the lifting tool, motor axes 2, 3, 4 to the motor.


•


Fit guide pins in the two lower holes for motor attachment screws .

For art. no. see:

•


Shown in the figure in:

•


6

CAUTION


7

8

9

Lift the motor onto the guide pins and guide it as close to the correct position as possible without pushing the motor all the way into the gear.

Remove the lifting tool and allow the motor to rest on the guide pins.


See section

•



• + = pin 2

• - = pin 5





359

4 Repair


Continued

10

Action

Use the rotation tool in order to rotate the motor pinion when mating it to the gear.

Note


•


xx0200000165


11 Fit the motor into its position making sure that:

• the motor pinion is properly mated to the gear of the gearbox axis 3


• the motor is turned the right direction, that is cables facing forwards. See the figure in


.

12

13

14


Secure the motor with its attachment screws.



M10x40

4 pcs


Use this procedure to connect all connectors motor axis 3.

1

2

3

4

5

Action

Fit a new gasket in the cable gland.

Note


•


Reconnect all connectors on motor axis 3.

Connect in accordance to markings on connectors.

Refit the cable gland cover at the cable exit with its attachment screws.

Make sure the cable gland cover is tightly sealed.

Shown in the figure in:

•


Refit the cover of motor axis 3.


Apply rust preventive (Mercasol ) on the upper arm housing outside the motor flange as a protection of the broken paint. layers.


•


Prime on page 355





4 Repair


Continued



1

2

3

4

5

Action

Remove the equipment used to unload the upper arm.


Note

See section

•


Refill gearbox axis 3 with oil .

See section

•








6

DANGER






361

4 Repair



Introduction



•


•

Preparation of the upper arm housing before fitting the motor on page 366

•


•


•



The motor axis 4 is located on the left hand side of the upper arm as shown in the figure.

xx0200000202

A

B

C

Motor axis 4

Cable gland cover


Required parts

Part

Motor

O-ring

Gasket


362

Spare part no.

See chapter:

• Spare parts

21522012-430

3HAC3438-1

Note

Includes:

• motor

• M10NB pinion

• o-ring

Must be replaced when reassembling motor.





4 Repair


Continued


Equipment

Grease

Removal tool motor M10x

Guide pins

Guide pins

Art. no.

3HAC3537-1

3HAC14972-1

3HAC15520-1

3HAC15520-2

Note

Used to lubricate o-ring.


M8x100


M8x150



Rotoation tool

Power supply -

3HAC12342-1

3HAC17105-1

Standard toolkit -

Calibration Pendulum toolkit 3HAC15716-1




Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Art. no.

3HAC034903-001

3HAC026759-001

12340011-116

Note

Mercasol


24 VDC, max. 1.5 A

For releasing brakes.



.



CAUTION



.





363

4 Repair


Continued



1

Action Note

Move the robot to a position where the upper arm is pointing straight up.

This position enables the motor to be replaced without draining the oil from gearbox axis 4. This saves time.

If needed, draining of oil is described in section:

•


Note

If the upper arm is placed in any other position draining of oil from gearbox is required!

2

DANGER

Turn off all:



3

CAUTION


See


4 Remove the cable gland cover at the cable exit of motor axis 4.

Make sure the gasket is not damaged!

See the figure in:

•






4 Repair


Continued

5

Action

Cut the paint layer with a knife in the joint between the cover and motor housing to avoid that the paint cracks.

Note

Figure showing the principal method!

xx0900000121

A

B

C

D

6

7

8

9

10 xx0600002874

Cut the paint layer with a knife in the joint between the motor and the upper arm housing to avoid that the paint cracks.


Remove the cover for connector access on top of the motor.


Keep the old cover with the air nipple fitted.



• C: Cover

• D: Motor axis 4




• + = pin 2

• - = pin 5

See section

•


CAUTION

Axis 4 might move when the brake is released and the balance of the axis is settled!

11

12

Unscrew the motors attachment screws with washers.

See the figure in:

•


Fit guide pins in two of the holes.


•






4 Repair


Continued

13

14

15

16

Action Note

If required, press the motor out of position by fitting removal tool, motor to the remaining holes.


•



Lift the motor up to get the pinion away from the gear.


Remove the motor by carefully lifting it straight up.

Make sure the motor pinion is not damaged!

Preparation of the upper arm housing before fitting the motor

Use this procedure for the preparation of the upper arm housing before refitting motor axis 4.

1

2

3

Action

Grind the paint edge on the surface carefully in order to get a smooth surface.

Note




•


Prime on page 363

xx1000000617

Part:

• A: Loctite 574



Action

1

DANGER

Turn off all:



Note







4 Repair


Continued

3

4

5

6

7

8

Action Note


Lubricate the o-ring with some grease .


•




• + = pin 2

• - = pin 5

Fit guide pins in two of the holes for the attachment screws of motor axis 4.


•


See the figure in:

•


Lift the motor onto the guide pins and guide it as close as possible without pushing the motor all the way into the gear.



• + = pin 2

• - = pin 5

See section

•


Use the rotation tool in order to rotate the motor pinion when mating it to the gear.


•


9

10

11

12 xx0200000165

Part:


Fit the motor in its position making sure that:

• the motor pinion is properly mated to the gear of gearbox axis 4


• the motor is turned the right direction, that is with cable exit hole facing downwards. See the figure in


.


Secure the motor with its attachment screws.



M8x25

4 pcs





4 Repair


Continued



1

2

3

4

Action

Fit a new gasket in the cable gland.

Note


•


Reconnect all connectors to motor axis 4.

Refit the cover of the motor.



See the figure in:

•


Make sure the cable gland cover is tightly sealed.



1

Action Note

Apply rust preventive (Mercasol) on the upper arm housing outside the motor flange as a protection of the broken paint layers.

For article number see

•


Prime on page 363

2

3

4

5 xx1000000618

Parts:

• A: Mercasol on cover and motor housing

• B: Attachment screws (4 pcs)

• C: Mercasol on upper arm housing outside motor flange

Apply rust preventive (Mercasol) on the attachment screws of the motor.


Apply rust preventive (Mercasol) over the joint between the cover and the motor housing as a proterction of the broken paint layers.


Only if gearbox has been drained.


Only if gearbox has been drained.

Refill the gearbox with oil.

See section

•


See section

•






4 Repair


Continued

6

Action


7

DANGER



.

Note




.




369

4 Repair



Introduction



•


•

Removing the pinion on motor axis 5 on page 374

•

Refitting the pinion on motor axis 5 on page 375

•


•


•


Reused pinion

Note

The pinion in motor axis 5 is matched with the bevel gear for axis 5. When the motor is replaced the pinion therefore must be removed from the dismounted motor and be fitted to the new motor.


The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit. See figure!

xx0200000204

A

B

C

Motor axis 5 (inside upper arm tube)

Upper arm tube

Wrist unit





4 Repair


Continued

Required parts

Parts

Motor axis 5

O-ring

Set of shims, motor

Gasket


Equipment

Rust preventive

Sikaflex 521FC

Spare part no.

Note



Includes:

• motor

• o-ring

NOTE!

Pinion is not included!

21522012-430

3HAC7941-28

3HAC3438-1

Must be replaced when reassembling the motor!

Used to optain the correct distance between motor flange and outer surface of motor pinion.

Must be replaced if the cabling is dismantled from the motor.


Equipment

Grease

Isopropanol

Mineral oil

Oil injector

Press fixture (for pinion) -

Art. no.

3HAC3537-1

11771012-208

CS 320

3HAC021590-001

Note


For cleaning motor pinion shaft and pinion hole.

For lubrication of motor pinion shaft and pinion hole.

500 MPa

For pressing out the pinion, motor axis

5.

For pressing the pinion on to the new motor.

Measuring tool

Removal tool motor

Extension bar for bits 1/2"

Guide pins

Guide pins

Power supply

Standard toolkit

-

-

6896134-GN

3HAC14972-1

3HAC12342-1

3HAC15520-1

3HAC15520-2

Always use the removal tool in pairs!

300 mm



24 VDC, max. 1.5 A




.


-



Art. no.

3HAC034903-001

3HAC026759-001

Note

Mercasol





4 Repair


Continued

Equipment

Loctite 574

Brush

Art. no.

-

12340011-116

Note

CAUTION





Action Note

1

DANGER

Turn off all:



2

CAUTION


See


3 Drain the oil from gearbox axis 5.

See section

•


4 Cut the paint layer with a knife in the joint between the wrist unit and the upper arm tube to avoid that the paint cracks.

xx0900000121

5

6

Remove the wrist unit .

Place the wrist safely on a workbench, in a fixture or similar.

See section

•

Replacement of complete wrist unit on page 263





4 Repair


Continued

7

Action

Cut the paint layer with a knife in the joint between the cover and the motor housing to avoid that the paint cracks.

Note


8 xx0600002904

Parts:

• A: Cover


• C: Attachment screws (4 pcs)

• D: Motor housing

Remove the cover for connector access on motor axis 5.


9

Note

Keep the old cover with air nipple fitted.

10

11

12

13

14

Disconnect all connectors to motor axis 5.

Remove the separate cable of motor axis

5.

To release the brakes connect the 24VDC power supply.

Connect in one of these ways: to connector R4.MP5 (in the motor):

• + = pin 2

• - = pin 5 or: to connector R3.MP5 (on the separate cable to motor axis 5, if not removed):

• + = pin C

• - = pin D

Unscrew the attachment screws of motor axis 5 and remove screws and plain washers.

Fit guide pins in two of the holes for the attachment screws of motor axis 5.


•






4 Repair


Continued

15

16

17

18

Action

Remove motor axis 5 by carefully lifting it straight up in order to get the pinion away from the gear.


Note

If required, press the motor out of position by fitting removal tool, motor M10x to the remaining holes.


•


Always use the removal tools in pairs and diagonally!


Note

Keep track of the shims between the motor flange and wrist housing!

Removing the pinion on motor axis 5

Use this procedure to remove the pinion of motor axis 5

1

2

3

Action Note

Measure the distance between the motor flange, including shims and the outer surface of the pinion with the measuring tool .

Make a note of measured distance!


•


Press out the pinion from the removed motor with the equipment included in the oil injector kit.


•


Note

If the pinion is damaged, the complete wrist unit must be replaced!

See section

•


Preparation of the wrist housing before fitting motor axis 5

Use this procedure for the preparation of the wrist housing before refitting motor axis 5.

1

2

Action



Note





4 Repair


Continued

3

Action

Apply rust preventive (Mercasol) on the outside of the machined surface.

Note


•


Prime on page 371

xx1000000621

Refitting the pinion on motor axis 5

Use this procedure to refit the pinion of motor axis 5

Action Note

1

DANGER

2

3

Turn off all:



Clean the pinion and the hole for the pinion on the motor with Isopropanol .


•


Note

If the pinion is damaged the complete wrist unit must be replaced!

See section

•


4

5

Apply a thin film of mineral oil to the shaft of the pinion and in the hole for the pinion on the motor to make the pinion run smoothly when being fitted.

This is necessary in order to achieve an even friction torque when fitting the pinion.


•


Place the motor and the pinion in a press fixture .





375

4 Repair


Continued

6

Action Note

Press the pinion onto the new motor.

Check the pressing force!

For an axis with diameter of 15.5 mm use:

• minimum pressing force = 18.5 kN

• maximum pressing force = 39.5 kN.

Note

If the pressing force is outside the given range or if the pinion "jumps" in bit by bit, it must be dismounted, checked and oiled before it is fitted again!

7

8

Measure the distance between the motor flange and the outer surface of the pinion with the measuring tool .


•


Modify the distance with shims to obtain the same distance as measured when dismounting the old motor (+0-0.05 mm)


•



Use this procedure to refit motor axis 5

1

2

Action



Note

Note

The pinion of motor axis 5 is matched with the bevel gear for axis 5. When fitting a new motor the pinion from the old must be fitted on the new motor!

How to remove the pinion is described in:

•

Removing the pinion on motor axis

5 on page 374

How to fit the pinion is described in:

•

Refitting the pinion on motor axis

5 on page 375

3 Apply Loctite 574 on the motor flange.


•


Prime on page 371

xx1000000623

Part:

• A: Loctite 574





4 Repair


Continued

4

Action

Place the number of shims needed.


• Apply Loctite 574 on the top one.

Note

Do not apply Loctite 574 between the shims!

Note


•


Prime on page 371

5

6

7

8

9

10 xx1000000622

Parts:

• A: Loctite 574

• B: Shims

In order to release the brake, connect the

24 VDC power supply.

Connect in one of these ways: to connector R4.MP5 (in the motor):

• + = pin 2

• - = pin 5 to connector R3.MP5 (on the separate cable to motor axis 5, if not removed):

• + = pin C

• - = pin D

Fit guide pins in two of the attachment holes for the motor.


•


Lift the motor onto the guide pins and guide it carefully into the gear making sure that:

• the motor pinion is properly mated to the gear of gearbox axis 5

• the motor pinion does not get damaged.

Secure the motor with its attachment screws and plain washers.


M8x25

4 pcs.

Apply rust preventive Mercasol on attachment screws and washers after tightening.


•


Prime on page 371




1

Action

Fit a new gasket on the cable gland.

Note


•


2 Refit the separate cable of motor axis 5.





4 Repair


Continued

3

4

5

Action

Connect all connectors to motor axis 5.


Refit the motor cover.

Note




1

Action


Apply rust preventive (Mercasol) over the joint between the cover and housing of motor axis 5 as a protection of the broken paint layers.

Note

378

2 Perform a leak-down test !

3 Refit the wrist unit .

4 Refill gearbox axis 5 with oil .


xx0600002904

Parts:

• A: Cover


• C: Attachment screws

• D: Motor housing axis 5

See section

•


See section

•


See section

•





.




4 Repair



Introduction



•


•

Preparation of the tilthouse before fitting a new motor on page 383

•

Preparation of motor axis 6 before fitting on page 383

•



The motor axis 6 is located in the center of the wrist unit as shown in the figure.

Required parts xx0700000126

A

B

C

Gearbox axis 6

Motor axis 6


Part

Motor, including pinion

O-ring

Gasket

Gasket, cover

Spare part no.

See chapter Spare parts .

21522012-430

3HAC048560-001

3HAC033489-001

Note

Includes:

• Motor

• Pinion

• O-ring


Must be replaced when replacing motor.

Must be replaced when opening cover.





4 Repair


Continued


Equipment

Grease

Removal tool, motor

M10x

Art. no.

3HAB3537-1

3HAC14972-1


Guide pins

3HAC12342-1

3HAC15520-1

Guide pins

Power supply -

3HAC15520-2

Standard toolkit -



See references to these procedures in the stepby-step instructions below.

-

Circuit diagram

3HAC15716-1


Equipment

Rust preventive

Sikaflex 521FC

Loctite 574

Brush

Art. no.

3HAC034903-001

-

3HAC026759-001

12340011-116

Note

For lubricating o-ring

Always use removal tools in pairs!

300 mm

M8x100


M8x150


24 VDC, max 1.5 A




.

Complete kit that includes user manual.


See chapter Circuit diagram .

Note

Mercasol

CAUTION





1

Action Note

Move the robot to a position where the motor axis 6 is pointing upwards. This position enables the motor to be replaced without draining the oil in gearbox axis 6. This will save time.

See the figure in:

•






4 Repair


Continued

Action Note

2

DANGER

Turn off all:



3

CAUTION


See


4 Cut the paint layer with a knife in the joint between the rear motor cover and motor housing in order to avoid the paint layer cracking.

Figure showing the principal method.

xx0900000121

5

6

Remove the rear motor cover .

Keep the old rear motor cover with the air nipple .

xx0600002885

Parts:

• A: Motor housing


• C: Air nipple (only Foundry Prime)

• D: Rear motor cover

• E: Gasket





4 Repair


Continued

7

8

9

10

Action

Disconnect all connectors of motor axis 6.

To release the brakes connect the 24 VDC power supply.


• + = pin 2

• - = pin 5

Note

If required, press the motor out of position by fitting the removal tool, motor to the attachment holes of the motor.


•



Remove the motor by carefully lifting it straight up away from the gear.


11 Disconnect the 24 VDC power supply.

xx0600003038

Parts:

• A: Tilthouse

• B: Motor axis 6






4 Repair


Continued

Preparation of the tilthouse before fitting a new motor

Use this procedure for the preparation of the tilthouse before fitting a new motor.

Note

1

Action

Clean the machined surfaces inside the tilthouse as described in the figure.

2 xx1000000624

Surfaces to be cleaned:

• A: at the position for the motor flange

• B: at the position for the o-ring on the motor

• C: at the position for the gasket.

Apply Loctite 574 on the machined surface for motor flange previously cleaned.

See A in the figure above!


•


Prime on page 380

Preparation of motor axis 6 before fitting

Use this procedure for the preparation of a new motor axis 6.

1

Action Note

Only applicable if a new spare part is used.

Fit a new gasket on the motor by removing the protection strip and paste it on the new motor.


•


xx1000000625

Part:

• A: Gasket





383

4 Repair


Continued

2

Action Note

Fit a new gasket cover on the old cover with the air nipple.


•


xx1000000626

• Gasket cover



1

2

3

4

Action



Note

Make sure the o-ring on the circumference of the motor is seated properly. Lubricate the o-ring with grease.


•



Connect the connector R3.MP6:

• + = pin 2

• - = pin 5

Fit guide pins in two of the holes for the motors attachment screws.


•






5

Action

Fit the motor with guidance from the guide pins making sure the motor pinion is properly mated with the gear of gearbox axis 6.

Make sure the pinion on the motor shaft is not damaged!

Note

4 Repair


Continued

6

7

8 xx0600003038

Parts:

• A: Tilthouse

• B: Motor axis 6



Secure the motor with its attachment screws .


M8x25

4 pcs

Apply rust preventive (Mercasol) on the attachment screws and plain washers after tightening!


•


Prime on page 380

9

10

11


Reconnect all connectors on motor axis 6.

Refit the cover on top of the motor.






385

4 Repair


Continued

12

Action

Apply rust preventive (Mercasol) over the joint between the rear motor cover and the motor housing as a protection of the broken paint layers.

Note xx0600002885

Parts:

• A: Motor housing


• C: Air nipple (only Foundry Prime)

• D: Rear motor cover

• E: Gasket







15

DANGER



.




4 Repair

4.7.1 Replacing gearbox axis 1

4.7 Gearboxes

4.7.1 Replacing gearbox axis 1

Introduction

This section describes how to replace gearbox axis 1.

This section consist of the following parts:

•

Removing gearbox axis 1 on page 391

•

Preparation of the frame before refitting gearbox axis 1 on page 393

•

Preparation of the base before refitting gearbox axis 1 on page 393

•

Preparation of the spare part before refitting on page 394

•

Refitting gearbox axis 1 on the base - Foundry Prime on page 397

•

Refitting base with gearbox on the mounting site on page 397

•

Refitting the complete arm system to the base - Foundry Prime on page 398

•

Refitting protection pipe and cable guide - Foundry Prime on page 401

•

Refitting the concluding parts - Foundry Prime on page 404





387

4 Repair


Continued

Location of gearbox axis 1 xx0600003068

D

E

F

A

B

C

Gearbox axis 1, RV 320C-191.35

Attachment screws M12x80 quality 12.9 Gleitmo (16 pcs)


Base

Frame

Protection pipe axis 1


.

Equipment

Gearbox

Cable guide

Radial sealing

Hex socket head cap screw

Spare part no.

See


.

3HAC024286-001

3HAC11581-4

3HAB3409-86

Art. no.

Note

Includes:

• O-ring 3HAB3772-93

Washer 3HAA1001-186

M16x60

Gleitmo 12.9

(12 pcs)

17x215x3

(12 pcs)





4 Repair


Continued

Equipment


Washer, serrated

O-rings

O-ring

Protection pipe, axis 1

Holder for bits

Press tool

Guide pin

Guide pin

Guide pins

Guide pins

Support base and gear axis 1

Lifting tool

Spare part no.

3HAB3409-74

3HAC026169-001

3HAB3772-97

3HAB3772-93

3HAC026892-001

Art. no.

Note

M12x80

Gleitmo 12.9

(16 pcs)

12.6x18x1.8

(16 pcs)

23x3.6

(3 pcs)

380.6x3.53

Replace only if damaged.

Replace only if damaged.

Bits SW10 3HAC029090-

001

3HAC026594-

001

3HAC022637-

001

3HAC13056-2

3HAC13120-5

For radial sealing

3HAC11581-4

M12x130

3HAC13120-4

3HAC15535-1

M12x150

M16x300

Always use the guide pins in pairs.

M16x250

Always use the guide pins in pairs.

Consists of four pieces.

3HAC15556-1

Lifting eye

Grease

Standard tools


See references to these procedures in the stepby-step instructions below.

-

3HAC025333-

005

3HAB3537-1

Used to lift gearbox axis 1 and frame.

(2 pcs)

Used together with lifting tool

3HAC15556-1.

For lubricating o-rings.



.


CAUTION



.





389

4 Repair


Continued

Cutaway view of gearbox axis 1

D xx1000000329

A

B

C

D

E

Cable guide

Surfaces to be lubricated with grease

Radial sealing

O-ring (3 pcs)

Protection pipe axis 1

E

A

B

C





4 Repair


Continued

Removing gearbox axis 1

Use this procedure to remove the gearbox for axis 1.


1

DANGER

Turn off all:



2

CAUTION


See


3

4

5

6

Remove the complete arm system .

See section

•


Remove the robot’s attachment bolts , in order to unfasten the base from the foundation.

See section

•

Orienting and securing the robot on page 86

Fit two M12 lifting eyes on each side of the gearbox.

For art. no. see:

•


Attach the lifting tool to the lifting eyes.

For art. no. see:

•


7

CAUTION

The complete gearbox unit and base weighs

241 kg together! (Base: 133 kg, gearbox unit: 108 kg.) All lifting equipment used must be sized accordingly!





391

4 Repair


Continued

8

Action

Lift the robot base with gearbox axis 1, to allow fitting of the support, base and gear axis 1 on the base.

Information

For art. no. see:

•


The figure shows IRB 6600 but the priciple is the same.

9

10

Fit the support, base and gear axis 1.

Make sure the base remains in a stable position before performing any work underneath the base!

Unscrew the 12 attachment screws and washers securing the gearbox to the base.

xx1000000364

• A: Support, base and gear axis 1

(4 pcs)

11

CAUTION

The gearbox weighs 108 kg! All lifting equipment used must be sized accordingly!

xx0600003069

• A: Gearbox axis 1

• B: Attachment screw, M16x60

12

13

14

Remove the gearbox.

Remove the cable guide and radial sealing .

See the figure in:

•

Cutaway view of gearbox axis 1 on page 390

Remove the protection pipe axis 1 from the removed gearbox.

See the figure in:

•






4 Repair


Continued

Preparation of the frame before refitting gearbox axis 1

Use this procedure for the preparation of the frame before refitting the gearbox axis 1.

1

2

3

Action

Remove residues of old sealing (Sikaflex) located between the gearbox unit and the frame as shown in the figure.

Apply grease on the surface between gearbox unit and frame (A) .

Clean the guidance edges and the joint surface carefully.

Note xx1000000335

• A: Surface between gearbox unit and frame

• B: Guidance edge

• C: Joint surface

Preparation of the base before refitting gearbox axis 1

Use this procedure for preparation of the base before refitting the gearbox axis 1.

1

Action

Clean the joint surface on the base carefully and check that the corresponding surface on the frame also is clean.

Note

2

3

4 xx1000000336

• A: Guidance edge

• B: Joint surface

• C: Mercasol

Clean the painted surface outside the guidance edge.

Remove old corrosion coating from the guidance edge carefully.

See the figure above.

Apply Mercasol on the surface outside the guidance edge.


Note

Make sure there is no Mercasol on the joint surface.





4 Repair


Continued

Preparation of the spare part before refitting

Use this procedure for preparation of the spare part before refitting it on Foundry

Prime robots.

1

Action

Check that the spare part (option Foundry

Prime) is painted as shown in the figure.

Note

A

25 B

B

2 Make sure the o-ring is fitted to the gearbox as shown in the figure to the right.

Lightly lubricate the o-ring with grease.

A

C xx1000000330

• A: Painted surfaces

• B: Unpainted surface

• C: Gearbox xx1200000674

A O-ring





3

Action

Apply Sikaflex 521FC in the gap at the end of the center tube as shown in the figure.

Note

4 Repair


Continued

4 Apply Mercasol on surfaces on the gearbox unit, as described in the figure.

A xx1000000332


• B: Center tube of gearbox

B xx1000000333

• A: Mercasol

• B: Gearbox





395

4 Repair


Continued

5

Action

Apply Mercasol inside the center tube of the gearbox unit as shown in the figure.

Note

6 Pre-assemble the protection pipe axis 1 inside the center tube. The upper edge of the protection pipe shall be about 30 mm below the upper edge of the center tube.

xx1000000334

• A: Grease on surfaces

• B: Center tube of gearbox

• C: Mercasol


396 xx1000000331

• A: Upper edge of center tube

• B: Upper edge of the protection pipe

• C: About 30 mm

Use 2x M6x50 screws to fix the protection pipe in this temporary position.

Note

The two M6x50 screws shall be replaced by two stainless M6x16 when the sealing ring has been installed.




4 Repair


Continued

7

Action Note

Fit the three o-rings in the oil filling holes on the gearbox. Use some grease to secure that they remain in place during the continued assembly.

See the figure in:

•


Refitting gearbox axis 1 on the base - Foundry Prime

Use this procedure to refit gearbox axis 1 on the base of a Foundry Prime robot.

1

2

3

Action

Check that both joint surfaces are clean.

Clean if necessary!

Note

Note

Before the start of refitting the gearbox, the necessary preparation procedures must be performed in order to get optimum result.

See


•


•


•

Preparation of the spare part before refitting on page 394

See


•


and


Fit M16 guide pins in two corresponding attachment holes on the gearbox.

Note

Make sure that the lifting eyes will not damage the o-ring.

Note

Make sure that the lifting chain will not damage the gear wheel during the lifting procedure.

4

5

Place the gearbox unit carefully on the guide pins and lower it in position.

Remove the guide pins and secure the gearbox with its attachment screws .

Note

Use new attachment screws and washers!

M16x60 quality 12.9 (12 pcs)


Refitting base with gearbox on the mounting site

Use this procedure to refit the base with gearbox .

Note

1

Action

Apply Mercasol on washers and screw heads after tightening.

Note

Make sure that Mercasol is not used on washers and threads of attachment screws before tightening!





4 Repair


Continued

Action

2

CAUTION

The complete gearbox unit and base weighs

241 kg together! (Base: 133 kg, gearbox unit: 108 kg.) All lifting equipment used must be sized accordingly!

3 Lift the robot base and gearbox 1 in order to allow the removing of the support, base and gear axis 1 .

Note

4 Secure the base to the mounting site.

xx1000000364

• A: Support base and gear axis 1

See


•

Orienting and securing the robot on page 86

5 Remove the lifting eyes.

Refitting the complete arm system to the base - Foundry Prime

Use this procedure to refit the complete arm system to the base on Foundry Prime robots.

1

Action

Fit two M12 guide pins in the holes shown in the figure.

Note

2 Fit the lifting equipment on the complete arm system as described in section


.

xx0600003095

• A: Holes for M12 guide pins in gearbox axis 1 (2 pcs)

• B: Holes for attachment screws (16 pcs)





3

Action

Lower the arm system with the help from the guide pins fitted to the gearbox axis 1.

Enter the guide pins in the corresponding holes in the frame.

Note

Note

The refitting must be completely level. Make sure that the lifting device is adjusted prior to refitting of the arm system.

4 Repair


Continued

4 Fit the serrated lock washers on to the attachment screws.

Check that the serrated lock washers are turned the right way as shown in the figure.

xx0600003093

• A: Holes in the frame for guide pins, shown from above.

Note

Use new washers and attachment screws.

5

6

7

Fit the 16 attachment screws, before the arm system is completely lowered.

Remove the guide pins and replace them with the remaining attachment screws.

Lower the arm system into its place and secure the arm system to the base with its attachment screws.

xx0600003070



• C: Attachment screws M12x80 quality 12.9 (16 pcs)

Use new attachment screws.





399

4 Repair


Continued

8

Action Note

Tighten the screws with the correct tightening torque.


Tip

Use a torque wrench with a holder for bits as recommended in

Replacing gearbox axis

1 on page 387

.

The space is cramped.

9 Apply Mercasol on the attachment screws and washers.

Note

Mercasol shall be applied after the attachment screws has been tightened!

xx1000000362

• A: Attachment screw

• B: Holder for bits xx1000000363

• A: Attachment screw

• B: Mercasol





4 Repair


Continued

Refitting protection pipe and cable guide - Foundry Prime

Use this procedure to install the protection pipe and cable guide on Foundry Prime robots.

1

Action

Check that the protection pipe is temporarily installed as shown in the figure.

This is important to be able to use the press tool when installing the sealing ring.

Note

2 Lubricate the surfaces of the center tube with grease as shown in the figure.

xx1000000331

• A: Upper edge of center tube

• B: Upper edge of the protection pipe

• C: About 30 mm

3 xx1000000365

Install the sealing ring with the press tool .

Use a plastic mallet .

• A: Surfaces to be lubricated with grease

• B: Center tube

For art. no. see:

•


xx1000000366

• A: Plastic mallet

• B: Press tool





4 Repair


Continued

4

Action

Check that the sealing ring is in the correct position. The groove for locking the cable guide shall be visible as shown in the figure.

Note

B

5 Adjust the protection pipe to the correct position as shown in the figure by pushing it up inside the center tube .

xx1000000367

• A: Sealing ring

• B: Groove

Note

The protection pipe is accessible from inside the base.

xx1000000368

• A: Groove

• B: Correct position of protection pipe

• C: Protection pipe

• D: Center tube





4 Repair


Continued

6

Action

Replace the two screws temporarily used to secure the protection pipe , with two stainless attachment screws M6x16.

Note

View from below.

7 Apply Mercasol on surfaces as shown in the figure.

xx1000000369



8 Install a new cable guide by pressing it down into position as shown in the figure.

Note

The cable guide shall be locked in position by the groove.

xx1000000370

• A: Mercasol


• C: Sealing ring xx1000000371

• A: Groove

• B: Cable guide

• C: Protection pipe

• D: Center tube





403

4 Repair


Continued

9

Action

Apply Sikaflex 521FC outside the cable guide as shown in the figure.

Note xx1000000372


• B: Cable guide

Refitting the concluding parts - Foundry Prime

Use this procedure to refit the concluding parts on Foundry Prime robots.

1

2

3

4

Action

Refit the lower end of the cable harness .

Refit motor axis 1 .

Fill oil in gearbox axis 1.


Note

See section

•

Replacing cable harness, axes 1-

6 on page 222

See section

•


See section

•





5

DANGER






4 Repair



Introduction

This section describes how to replace gearbox axis 2. It describes the procedures for both.


•

Preparations before removing gearbox axis 2 on page 407

•

Removing the armsystem on page 410

•


•

Preparation of the frame before refitting of gearbox axis 2 on page 412

•

Preparation of the lower arm before refitting of gearbox axis 2 on page 413

•

Preparation of the spare part before refitting of gearbox axis 2 on page 413

•

Refitting gearbox axis 2 to the frame on page 415

•

Refitting the armsystem to gearbox axis 2 on page 417

•

Refitting the cable harness on page 418

•

Concluding refitting procedure on page 418

Location of gearbox axis 2

The gearbox axis 2 is located in the lower rotational center.

xx0700000357

A

B

C

D

Attachment screws, M16x50 quality 12.9 Gleitmo (20 pcs)

Attachment screws, M12x60 quality 12.9 Gleitmo (32 pcs)

Gearbox axis 2

Motor axis 2





4 Repair


Continued


Equipment

Gearbox axis 2

Art. no.

Note



.

Includes:

• Gearbox


O-ring 3HAB3772-91

Hex socket head cap screw 3HAB3409-84

Washer


Washer

Grease

3HAA1001-186

3HAB3409-71

3HAA1001-134

3HAB3537-7

M16x50

Quality 12.9 Gleitmo

(20 pcs)

17x25x3

(20 pcs)

M12x60


(32 pcs)

13x19x1.5

(32 pcs)

For lubricating o-rings

Lifting tool

Roundslings

Shackle -

-

3HAC025214-001 For lifting gearbox

Lifting eye VLBG M12 3HAC16131-1

Used for lifting the lower and upper arm without needing to use a hoisting block.

Used for lifting the lower and upper arm without needing to use a hoisting block.

Dismantling and mounting tool

Guide pins

3HAC028920-001

3HAC13056-4

Guide pins

Guide pins

Guide pins

Crank

Standard toolkit -

3HAC13056-3

3HAC022637-001

3HAC13056-2

3HAC020999-001

M12x250

Always use in pairs

M12x200

Always use in pairs

M16x130

Always use in pairs

M16x150

Always use in pairs

Used to turn the gear in the correct position









4 Repair


Continued

Additional equipment, Foundry Prime

Equipment

Sikaflex 521FC

Loctite 574

Rust preventive

Brush -

Art. no.

3HAC026579-001

12340011-116

3HAC034903-001

Note




Equivalent:

• Mercasol


CAUTION



.

Preparations before removing gearbox axis 2

Use this procedure in order to make the necessary preparations for the removal of gearbox axis 2.

1

2

3

Action

Unload the balancing device.

Information

Method 1 is described in section:

•


Method 2 is described in section:

•


Remove the front shaft using the dismantling and mounting tool .

For art. no. see:

•


How to use the tool is described in sections:

•

Replacing the balancing device

(design 1) on page 302

•

Replacing balancing device (design

2) on page 311

Jog the robot to the following position:

• Axis 2 = -60°

• Axis 3 = +60° xx0700000351





407

4 Repair


Continued

Action

4

CAUTION

The upper and lower arms (incl. gearboxes axes 2 and 3) weighs 455 kg. All lifting equipment used must be sized accordingly!

5 Method 1 for lifting the upper and lower arms:

Fit the lifting tool on the upper and lower arms as shown in the figure, and secure the robot in an overhead crane.

Information xx0700000350

Parts:

• A: Lifting eye (armhouse)




• E: Lifting chain

• F: Roundsling (put in a loop around the wrist on the inside)

• G: Roundsling (put in a loop around the lower arm)





4 Repair


Continued

6

Action

Method 2 for lifting the upper and lower arms:

1 Fit the lifting accessories on the upper and lower arms as shown in the figure, and secure the robot in an overhead crane.

2 Jog axis 3 so that roundsling F is stretched.

Information

7 Raise the crane to reach lifting center and straighten the chains.

xx1200000675



• C: Shackle and lifting eye VLBG

M12



• F: Roundsling (1.5 m)

8 Release the brakes of axis 2 to let the weight of the arm system settle in the lifting accessories.

xx0900000112





409

4 Repair


Continued

9

Action


Information

See section

•


Removing the armsystem

Action

1

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before entering the workspace of the manipulator.

Also read the safety sections:

•

Safety risks related to pneumatic/hydraulic systems on page 36

•

Risks associated with live electric parts on page 32

•

Safety risks during installation and service work on robots on page 26

Note

2

CAUTION


See


3

4

5

6

Remove the lower end of the cable harness.

See section

•

Removing the cable harness frame and base on page 226

Loosen the cable attachment from the lower arm and pull up the cabling carefully.

Let the removed part of the cable harness hang loose but be careful not to damage it during the continued removal process.

Remove the attachment screws securing the lower arm to axis-2 gearbox.

M16x50

See the figure in:

•

Location of gearbox axis 2 on page 405

Lift away the upper and lower arms and put them down on the floor.


Action

1

CAUTION


See


Note





4 Repair


Continued

2

Action

Remove motor axis 2 .

3 Remove two of the attachment screws

(M12x60 ) parallell to each other, securing the gearbox to the frame. (The holes shall be used for the guide pins .)

Note

See section

•


4 xx1000000376

Parts:

• A: Guide pins (2 pcs)

Fit two guide pins in the holes as shown in the figure.


5

CAUTION


6

7

Remove the remaining attachment screws

(M12x60) .

See the figure in:

•


Fit the lifting tool for lifting the gearbox and secure with a roundsling in an overhead crane or similair.

For art. no. see:


8 Remove the gearbox.

Use two M12 screws to push out the gearbox, if necessary.

xx1000000378

Parts:

• A: Lifting tool





4 Repair


Continued

Preparation of the frame before refitting of gearbox axis 2

Use this procedure to make the necessary preparations of the frame before refitting gearbox axis 2.

1

Action

Clean the machined surface in the frame as shown in the figure, from paint, oil, corrosion coating or other kinds of contamination.

Note

2

3

4 xx1000000379

Parts:

• A: Joint surface

• B: Surface for o-ring

• C: Machined surface

Clean the joint surface carefully, by removing old corrosion coating and/or flange sealing from the surface.

See figure above.

Clean the surface for the o-ring

Apply Mercasol on the

.

machined surface .

See figure above

See figure above

Note

Make sure there is no Mercasol on the joint surface!





4 Repair


Continued

Preparation of the lower arm before refitting of gearbox axis 2

Use this procedure to make the necessary preparations of the lower arm before refitting gearbox axis 2.

1

Action

Clean the joint surface and guidance edge on the lower arm as shown in the figure.

Note xx1000000385

Parts:

• A: Joint surface (dashed line)

• B: Guidance edge

Preparation of the spare part before refitting of gearbox axis 2

Use this procedure to make the necessary preparations of the spare part before refitting gearbox axis 2.

Note

1

Action

Check that the spare part is painted as shown in the figure.

xx1000000380

• A: Unpainted surfaces

• B: Painted surfaces





4 Repair


Continued

2

Action Note

Make sure that the o-ring (339.3x5.7) is fitted correctly on the new gear box unit.

For art. no. see:

•


3 Apply a layer of Mercasol , with a thickness of minimum 0.5 mm, on the unpainted surface of the gearbox, as shown in the figure.

Make sure the surface is covered properly, it should not be possible to see through the layer of Mercasol.

xx0600003128 xx1000000380

Parts:

• A: Mercasol (on unpainted surface)






4

Action

Clean the joint surface outside the o-ring.

Note

4 Repair


Continued

5 xx1000000383

Parts:

• A: Flange sealing (Loctite 574)

• B: Joint surface

Apply flange sealing (Loctite 574) on the joint surface outside the o-ring as shown in the figure.

See figure above.

Refitting gearbox axis 2 to the frame

Use this procedure to refit gearbox axis 2.

Action

1

CAUTION

Note


2 Fit the lifting tool , in the uppermost hole of the gearbox axis 2 and secure it with a roundsling in an overhead crane or similair.

For art. no. see:

•


xx1000000378

Part:

• A: Lifting tool





4 Repair


Continued

3

Action

Fit two guide pins in two of the holes for the attachment screws, parallell to each other.

Note

4

5 xx1000000376

Part:

• A: Guide pins (2 pcs)

Lift the gearbox on to the guide pins and push it to its mounting position.

Secure the gearbox with its screws with washers .

attachment

Note

Use new attachment screws and washers.


For art. no. see:

•


6 Install 2x M12x12 set screws in the threaded holes in the flange of the gearbox.

7 xx1000000384

Parts:

• A: Screw head

• B: Set screw (2 pcs opposite each other)

Apply Mercasol on all screw heads and set screws after tightening.

See figure above.





4 Repair


Continued

Refitting the armsystem to gearbox axis 2

Use this procedure to refit the armsystem to gearbox axis 2.

Action Note

1

CAUTION

The upper and lower arms (incl. gearboxes axes 2 and 3) weighs 455 kg. All lifting equipment used must be sized accordingly!

2 Fit the lifting tool on the upper and lower arms and secure the robot in an overhead crane.

3

4

5 xx0700000350

Parts:

• A: Lifting eye (armhouse)




• E: Lifting chain

• F: Roundsling (put in a loop around the wrist on the inside)

• G: Roundsling (put in a loop around the lower arm

Use a crank in the gearbox in order to find the holes for the attahment screws.

For art. no. see:

•


Secure the lower arm to gearbox axis 2 with its attachment screws and washers .

Note

Use new attachment screws and washers.


See the figure in:

•


For art. no. see:

•


Apply Mercasol on all screw heads of the attachment screws after tightening them.





4 Repair


Continued

Refitting the cable harness

Use this procedure to refit the cable harness.

1

Action

Apply Sikaflex 521FC on the cover (at the

SMB/BU units) mounted on the cable harness, before the harness is fitted in the hole in the frame.

Note

2

3


Refit the lower end of the cable harness .

xx1000000386

Parts:

• A: Hole (for cover)

• B: Sikaflex 521FC

• C: Cover

See section

•


See section

•

Replacing cable harness, axes 1-

6 on page 222

Concluding refitting procedure

Use this procedure for the concluding procedure of refitting.

1

2

Action

Fill gearbox axis 2 with oil.


Note

See section

•





.

3

DANGER



.




4 Repair



Introduction



•

Removal of gearbox axis 3 on page 422

•

Preparations of lower arm before refitting of gearbox axis 3 on page 424

•

Preparations of upper arm before refitting of gearbox axis 3 on page 425

•

Preparations of spare part before the refitting on page 426

•

Refitting gearbox axis 3 on the upper arm on page 427

•

Refitting the upper arm on page 428

•






419

4 Repair


Continued


The gearbox axis 3 is located in the upper rotational center.

xx0200000194

D

E

F

A

B

C

Gearbox, axis 3

Motor, axis 3

Upper arm



Washer (3 pcs)


Equipment

Gearbox

Spare part no.


Art no.

Note

Includes:

• Gearbox






4 Repair


Continued

Equipment

Attachment screw

Washer

Attachment screw

Washer

Sealing, axis 2/3

O-ring

Grease

Mechanical stop axis

3

Washers

Bolt

Lifting eye

Guide pins

Guide pins

Guide pins

Guide pins

Standard toolkit

Spare part no.

3HAB3409-71

3HAA1001-134

3HAB7700-69

3HAC038648-001

3HAC17212-1

3HAB3772-68

Art no.

Note

M12x60


24 pcs

13x19x1.5

24 pcs

M12x50


33 pcs

3 pcs

-

3HAB3537-1

3HAC12708-1

3HAA1001-186

3HAB3409-86

A new sealing must be used on each assembly.

Replace if damaged!

For lubrication of o-rings

Used to secure the upper arm.

Use attachment screws

3HAB3409-86, M16x69

For mechanical stop axis 3

M16x60

For mechanical stop axis 3

3HAC025333-005 M12

3HAC13056-3 M12x200

For guiding gearbox


3HAC13056-4

3HAC14628-1

M12x250

For guiding gearbox


80 mm

For guiding sealing ax 2/3


3HAC14628-2 100 mm

For guiding sealing ax 2/3






3HAC15716-1 Complete kit that also includes operating manual






4 Repair


Continued

Additional equipment, Foundry Prime

Equipment

Rust preventive

Loctite 574

Brush

Spare part no.

Art. no.

3HAC034903-001

-

12340011-113

Note

Mercasol

CAUTION



Removal of gearbox axis 3

Use this procedure to remove gearbox axis 3.

3

4

1

2


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 273

.

Rotate axis 5 to position +90°.

DANGER

Turn off all:



5

CAUTION


See


6

7

8

Drain the axis-3 gearbox.

See section

•


Secure the upper arm in a horizontal position, using roundslings fitted in the lifting eye on the upper arm.

How to lift and remove the upper arm is decribed in section:

•

Removal, upper arm on page 276

Remove motor axis 3 .

See section

•


DANGER

When removing motor axis 3, the brake on axis 3 i released. Make sure the upper arm is secured and disabled from moving.





4 Repair


Continued

9

Action

Remove the upper arm .

Information

See section

•

Removal, upper arm on page 276

10 Remove the sealing axis 2/3 between gearbox and lower arm.

Note

On reassembly a new sealing must be used! For art. no. see:


.

11

12

Place the removed upper arm safely on a workbench, in a fixture or similar.

Remove the attachment screws that secure the axis-3 gearbox to the upper arm.

See the figure in:

•


13

14

Fit two guide pins in 180° relation to each other in the holes for the attachment screws of the gearbox.

For art. no. see:

•


If required, use two M12 screws in the the holes shown in the figure, in order to press the gearbox free.

For art. no. see:

•


15

CAUTION


xx0200000201

• A: M12 holes for pressing the gearbox out

• B: Holes for attachment screws, between gearbox and upper arm

• C: Holes for attachment screws, between gearbox and lower arm

16

17

Fit the lifting eye to the gearbox.

Remove the gearbox with guidance from the guide pins. Use an overhead crane or similar.





423

4 Repair


Continued

Preparations of lower arm before refitting of gearbox axis 3

Use this procedure to make the necessary preparations of the lower arm before refitting gearbox axis 3.

Note

1

2

Action

Clean the machined surface on the lower arm where the gearbox axis is located.

Careful cleaning of:

• guidance edges for the gearbox in the lower arm

• joint surface

3 Apply Mercasol on the guidance edges as well as between these.

xx1000000432

Parts:

• A: Joint surface (3x)

• B: Guidance edge (3x)

• C: Lower arm xx1000000433

Parts:

• A: Mercasol on guidance edge

• B: Lower arm

• C: Joint surface (3x)

Note

Make sure that there is no Mercasol on the joint surfaces.





4

Action

Apply Loctite 574 on a new sealing ring on both sides.

Note

Note

Do not apply the flange sealing closer than

20 mm from the edge of holes as shown in the figure.

4 Repair



Parts:

• A: Surfaces with Loctite 574

• B: Maximum 20 mm from edge holes

Preparations of upper arm before refitting of gearbox axis 3

Use this procedure to make the necessary preparations of the upper arm before refitting gearbox axis 3.

1

Action

Clean the machined joint surface on the uipper arm housing.

Remove contaminations such as paint, oil, corrosion coating etc. from the surface.

Note

2 xx1000000435

Parts:

• A: Joint surface

• Surface for o-ring

Clean the surface for the o-ring in the upper arm housing.

See figure above.





425

4 Repair


Continued

Preparations of spare part before the refitting

Use this procedure to make the necessary preparations of the spare part before the refitting.

1

Action

Check that the spare part is painted as shown in the figure.

Note

2 xx1000000437

Parts:

• A: Unpainted surfaces

• B: Painted surfaces

Make sure that the o-ring is fitted on the new gearbox unit.

Dimension: 276x3.53

Tip

Apply some grease on the o-ring in order to make it stay in the groove during assembly.

xx0200000173

Part:

• A: O-ring, gearbox axis 3





3

Action

Apply Mercasol on the unpainted surface of the gearbox, as shown in the figure.

Note

4 Repair


Continued

4 Apply Loctite 574 on the flange outside the o-ring as shown in the figure.

xx1000000437

Part:

• A: Mercasol

• B: Painted surfaces xx1000000438

Part:

• A: Loctite 574

Refitting gearbox axis 3 on the upper arm

Use this procedure to refit gearbox axis 3 on the upper arm.

Action Note

1

DANGER

Turn off all:







4 Repair


Continued

2

3

Action Note

Turn the upper arm in such a position that the gear mating surface faces upwards.

Fit two guide pins in 180° relation to each other in the holes of the upper arm, used for the attachment screws of the gearbox

For art. no. see:

•


4

CAUTION


5

6

7

8

9

10

Lift the gearbox to its mounting position.

Turn the gearbox to align the holes of the attachment screws of the gearbox with those in the upper arm.

Place the gearbox on the guide pins and slide it carefully into position.

Make sure that:

• the o-rings are seated correctly

• the gearbox is correctly oriented.

Remove the lifting tool.

Secure the gearbox with 22 of the 24 attachment screws.


M12x60

Note


Refitting the upper arm

Use this procedure to refit the upper arm.

1

Action

Fill the hole for the slotted spring pin with

Sikaflex 521FC.

Note xx1000000439

Part:

• A: Hole for slotted spring pin





2

Action

Fit M12x16 bolts in the two M12 disassembly holes.

Note

Note

Max length 40 mm.

4 Repair


Continued

3

4 xx1000000440

Apply Mercasol on the heads of all M12 attachment screwsafter tightening.

See figure above.

Refit the upper arm .

Note

Use a new sealing axis 2/3 .

Parts:

• A: M12 bolt for disassembly, upper

• B: M12 bolt for disassembly, lower

• C: Attachment screw M12x60 (24 pcs)

How to lift and refit the upper arm is described in section:

•

Replacement of upper arm on page 273

For art. no. see:

•



Use this procedure for the concluding procedure of refitting gearbox axis 3.

1

2

3

Action

Refill gearbox axis 3 with oil.



Note

See section

•


See section

•





.





429

4 Repair


Continued

Action

4

DANGER



.

Note




4 Repair



Introduction


This section consists of the following parts:

•


•

Refitting gearbox axis 6 on page 434

•



The gearbox axis 6 is located in the center of the wrist unit as shown in the figure.

xx0200000219

A

B

C

-

D

Gearbox, axis 6

Attachment screws, M8x40 with washers (18 pcs)

Oil plug, draining

Oil plug, filling

O-ring (not shown in the figure)





431

4 Repair


Continued


Equipment

Gearbox, type 1

Gearbox, type 2

Attachment screw

Washer

O-ring (type 1)

O-ring (type 1)

O-ring (type 1)

O-ring (type 2)

O-ring (type 2)

O-ring (type 2)

Grease

Standard toolkit



Spare part no.

See Spare parts

See Spare parts

3HAB7700-55

3HAA1001-172

3HAB3772-58

3HAB3772-65

21520431-20

3HAB3772-57

3HAB3772-64

3HAB3772-61

-

Art. no.

3HAB3537-1

3HAC15716-1

Note

Includes:

• Gearbox


Includes:

• Gearbox


M8x40


18 pcs

8.4x13x1.5

18 pcs

152.0x3.53

Must be replaced when reassembling the gearbox.

131.0x2.0


15.5x1.5


6 pcs

164.7x3.53


150.0x2.0


13.1x1.6


12 pcs

For lubricating o-ring



Complete kit which also includes

Operating manual.


Required equipment - Foundry Prime

Equipment Spare part no.

Art. no.

Note

Rust preventive


432

3HAC034903-001 Mercasol




4 Repair


Continued

Equipment

Loctite 574

Brush

Spare part no.

Art. no.

-

12340011-116

Note

CAUTION



.


Use this procedure to remove gearbox axis 6.


1

DANGER

Turn off all:



2

CAUTION


See


3

4

5

Drain the oil

Remove the from gearbox axis 6.

turning disk .

See section

•


See section

•

Replacing the turning disk on page 259

Remove the gearbox by unscrewing its 18 attachment screws .

See section

•






433

4 Repair


Continued

6

Action

Only valid for type 2 of the wrist unit:

If required, fit two M8 screws in the holes in order to press out the gearbox.

Information

7 xx0200000220

Part:

• A: M8 holes for pressing out the gearbox

Remove the gearbox by lifting it out carefully.

CAUTION

Do not damage the pinion of the motor!

Refitting gearbox axis 6

Use this procedure to refit gearbox axis 6.

Action

1

DANGER

Note

Turn off all:



2 Make sure the o-ring is fitted to the rear of the gearbox.

Lubricate the o-ring with grease .





3

Action

Put grease on the surface of the guiding edge and on the contact surface for the RV gearbox in the tilthouse.

Note

4 Repair


Continued

4

5

6 xx1000000446

Parts:

• A: Surface of guiding edge and RV gearbox

• B: Loctite 574

Apply Loctite 574 on the joint surface of the tilthouse.


Release the holding brake of motor axis 6.

See section

•


Place gearbox axis 6 in the wrist unit.

Note

Make sure the gears of the gearbox mate with the gears of the motor!

For art. no. see:

• Spare parts

See the figure in:

•


7 Secure the gearbox with its screws and washers .


attachment

Note


See the figure in:

•


M8x40 quality 12.9 Gleitmo (18 pcs)





435

4 Repair


Continued


Use this procedure for the concluding procedure of refitting gearbox axis 6 on

Foundry Prime robots.

1

Action

Apply rust protection Mercasol on the attachment screws after tightening.

Note

2

3 xx1000000447

Apply rust protection Mercasol on surfaces shown in the figure.


Apply Loctite 574 on surfaces of the gearbox as shown in the figure.

Parts:


• B: Surfaces with Mercasol

4 Refit the turning disk .

5 Perform a leak-down test .

6 Refill gearbox axis 6 with oil .

xx1000000448

Part:

• A: Loctite 574

See section

•

Replacing the turning disk on page 259

See section

•


See section

•






4 Repair


Continued

7

Action


8

DANGER



Note







437


5 Calibration information

5.1 When to calibrate


5.1 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.




439


5.2 Calibration methods

5.2 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.

Calibration Pendulum

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

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).






5.2 Calibration methods

Continued

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.

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.

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.




441


5.3 Synchronization marks and synchronization position for axes

5.3 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 6640 and IRB 6640ID

The figure below shows the positions of the calibration marks on the robot.

442 xx0700000340

G

H

E

F

A

B

C

D

Calibration mark axis 1






Calibration mark axis 5, IRB 6640ID

Calibration mark axis 6, IRB 6640ID





5.4 Calibration movement directions for all axes

5.4 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




443


5.5 Updating revolution counters

5.5 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.

IRB 140, 1400, 2400, 4400, 6600ID/6650ID,

6640ID: Axes 5 and 6 must be positioned together!

See

Synchronization marks and synchronization position for axes on page 442 .

When all axes are positioned, update the revolution counter.

Step 2 - Updating the revolution counter with the FlexPendant on page 445 .

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 6640 -180/2.55

Axis 4

Yes

IRB 6640 - 235/2.55, 205/2.75,

185/2.8, 130/3.2

Yes

IRB 6640ID - 170/2.75,

200/2.55

Yes

Axis 6

No

Yes

No

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).







Continued

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

2 All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

xx1500000943





445



Continued

3

Action

A screen is displayed, tap Rev. Counters .

446 en0400000771

4

5

6

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.

7

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 447

.





5.6 Checking the synchronization position

5.6 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

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.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

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.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See


and





447


6 Decommissioning

6.1 Introduction



Introduction

This section contains information to consider when taking a product, robot or controller, out of operation.

It deals with how to handle potentially dangerous components and potentially hazardous materials.

General

All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit are installed.

If the robot or the control unit is partially or completely disposed of, the various parts must be grouped together according to their nature (which is all iron together and all plastic together), and disposed of accordingly. These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed.




449


6.2 Environmental information

6.2 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.






6.2 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.




451


6.3 Scrapping of robot

6.3 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.





6.4 Decommissioning of balancing device

6.4 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

Protective clothing that also covers face and hands

Cutting torch with a long shaft

-

-


-

Art. no.

Note



.

Must protect against spatter of sparks and flames.

For opening housing and cutting coils.

The long shaft is a safety requirement.


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

Decommissioning of balancing device on page 453

.

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.





453



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! When a coil is cut the released tension creates a spatter of sparks and flames.

The working area must be free of flammable materials. Position the balancing device so that the spatter will be directed away from personnel.

2 Clamp the device at the working location.

Place the device at ground level so that the hole and spring coils are cut from a more safe distance.

3

DANGER

The hole must be cut as specified in the figure. Pieces can be ejected from the cylinder at high speed if the hole is cut larger than specified!

4 Cut a hole in the housing as shown in the figure.

Use a cutting torch with a long shaft.

The measurements shown below are maximum values!

20

0 m m

40

0 m m xx0700000391







Continued

Action

5

DANGER

There is stored energy built up by high tensioned compression springs inside the balancing device! When a coil is cut the released tension creates a spatter of sparks and flames.

The working area must be free of flammable materials. Position the balancing device so that the spatter will be directed away from personnel.

Note

6

7

Cut the coils of the 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 with a long shaft.

Double-check the number of coils cut and make sure all the tension in the springs are removed.




455


7 Reference information

7.1 Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.




457


7.2 Applicable standards

7.2 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






7.2 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




459


7.3 Unit conversion

7.3 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





7.4 Screw joints

7.4 Screw joints

General

This section describes how to tighten the various types of screw joints on the IRB

6640 Foundry Prime.

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

11712016-618

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.






7.4 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


462


Class 12.9, lubricated

i

35





7.4 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




463


7.5 Weight specifications

7.5 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 1,340 kg (IRB6640), 1,405 kg

(IRB6640ID) .






7.6 Standard tools

7.6 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




465


7.7 Special tools

7.7 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 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

Extension 300mm for bits 1/2"

Guide pins M8 x 100

Guide pins M8 x 150



Lifting tool, wrist unit

Lifting tool, motor ax 1, 4, 5

Lifting tool, motor ax 2, 3, 4



Rotation tool


Bolts M16 x 60 (for mechanical stop axis 3)

Washers (for mechanical stop axis 3) 2

Standard toolkit (content described in section


)

1

1

2

2

2

2

1

1

1

2

2

2

Qty

1

2

Art. no.

3HAC12342-1

3HAC15520-1

3HAC15520-2

3HAC15521-1

3HAC15521-2

3HAC13605-1

3HAC14459-1

3HAC026061-001

3HAC14972-1

Fits motors, axes 4, 5 and 6.

3HAC14973-1

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

Distance tool

Gearbox crank, axis 2





466

1

1

1

Qty

1

1

Art. no.

3HAC030662-001

3HAC020999-001

3HAC022637-001

3HAC13056-2

3HAC13056-3





7.7 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


Lifting accessory, upper arm

Lifting accessory. lower arm

Lifting accessory, gearbox axis 3

Lifting eye

Lifting eye VLBG M12

Lifting eye M16


Lifting tool, gearbox axis 2

Measuring tool

Oil injector / max 500 MPa

Press gear axis 1


Shackle, balancing device

Support, base

Tool set balancing device

Art. no.

3HAC13056-4

3HAC13120-4

3HAC13120-5

3HAC14628-2

3HAC14628-1

3HAC029090-001

3HAC11731-1

3HAC13086-1

3HAC15994-1

3HAC027794-001

3HAC032724-001

3HAC025333-001

3HAC16131-1

3HAC14457-4

3HAC15556-1

3HAC025214-001

6896134-GN

3HAC021590-001

3HAC026594-001

3HAC020902-001

3HAC020997-001

3HAC15535-1

3HAC028920-001

2

1

2

1

1

1

1

1

1

1

1

Qty

1

1

1

1

1

1

1

1

1

1

1

1

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.





467


7.7 Special tools

Continued

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

Description


Art. no.

3HAC15716-1

Note

Complete kit that also includes operating manual.

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.





7.8 Dismounting and mounting tool 3HAC028920-001

7.8 Dismounting and mounting tool 3HAC028920-001

General

This section details how to configure the tool 3HAC028920-001 for dismounting and mounting the balancing device on the IRB 6640 Design 1 and Design 2. The difference in the design is described in

Design 1 and Design 2 of IRB 6640 on page 54 .

The following setups for the tool are described:

•

Tool description on page 470

•

Removal front shaft design 1 and 2 on page 471

•


•

Refitting front bearing and sealing Design 1 on page 477

•


•

Refitting front bearing with sealing Design 2 on page 480

•

Removal rear shafts Design 1 and 2 on page 481

•

Refitting rear shafts Design 1 on page 482

•

Refitting rear shafts Design 2 on page 484





469



Continued

Tool description xx0900000024

Item

1

2

Mark

A

Description

Hydraulic cylinder not included in tool 3HAC028920-001 (ordered separately).

Press tool D=103







Continued

6

7

8

Item

3

4

5

9

10

11

12

13

B

F

C

G

J

E

K

H

Mark

D

Description

Press tool D=54

Threaded bar, M16

Adapter M16/M20

Knurled nut D=80

Slide hammer / Distance

Nut M16

Press tool D=85

Press tool D=100

Press tool D=110

Press tool D=90

Press tool D=62

Removal front shaft design 1 and 2

The following configuration is used for removal of the front shaft Design 1 and 2.

In the figure only Design 1 is shown.

Configuration:

• 8

• C

• 4

• B xx0900000026





471



Continued

1) Assemble the adapter B into the shaft.

2) Assemble the threaded bar,

M16 into the adapter.

3) Assemble the

Slide hammer /

Distance on to the threaded bar,

M16.

4) Assemble the nut M16.

Alternative configuration:

• 4

• F

• 1

• A

• B xx0900000027 xx0900000028







Continued

1) Assemble the adapter B into the shaft.


M16 into the adapter.

3) Assemble the

Press tool D=103 on to the threaded bar,

M16.

4) Assemble the hydraulic press

5) Assemble the knurled nut D=80 xx0900000029

Refitting front shaft design 1 and 2

The following configuration is used for refitting of the front shaft Design 1 and 2.

Configuration:

• 8

• C

• 4 xx0900000063





473



Continued xx0900000091 xx0900000065






M16 (4).

2) Assemble the

Slide hammer /

Distance (C) on to the threaded bar, M16.

3) Assemble the nut M16 (8).




Removal front bearing Design 1

The following configuration is used for removal of the front bearing Design 1.

Configuration:

• D

• A

• C

• 8

• 4 xx0900000031





475



Continued

1) Assemble the press tool D=54

(D) onto the threaded bar (4).


M16 with the press tool through the assembled bearing.

3) Assemble the

Press tool D=103 on to the threaded bar,

M16.

4) Assemble the

Slide hammer /

Distance.

5) Assemble the nut M16.

Alternative configuration

• D

• A

• 1

• F

• 4 xx0900000032 xx0900000033






(D) onto the threaded bar (4).



3) Assemble the

Press tool D=103

(A) on to the threaded bar,

M16.


(1).

5) Assemble the

Knurled nut

D=80 (F).




Refitting front bearing and sealing Design 1

The following configuration is used for refitting of the front bearing and sealing

Design 1

Configuration:

• 4

• F

• E

• C

• 8 xx0900000036





477



Continued

1) Insert the threaded bar (4) through the new bearing and place it in the ear

2) Assemble the

Knurled nut D=80

(F).

3) Assemble the

Press tool D=85

(E).

4) Assemble the

Slide hammer /

Distance (C).

5) Assemble the

Nut M16 (8) xx0900000037

Removal front bearing Design 2

The following configuration is used for removal of the front bearing Design 2.

Configuration:

• H

• A

• C

• 8

• 4 xx0900000038






(H) onto the threaded bar (4).



3) Assemble the

Press tool D=103


M16.

4) Assemble the

Slide hammer /

Distance (C).


xx0900000039

Alternative configuration:

• H

• A

• 1

• F

• 4








479



Continued


(H) onto the threaded bar (4).



3) Assemble the

Press tool D=103


M16.


(1).

5) Assemble the

Knurled nut D=80

(F).

xx0900000041

Refitting front bearing with sealing Design 2

The following configuration is used for refitting of the front bearing with sealing

Design 2.

Configuration:

• 4

• F

• J

• 7

• 8 xx0900000042







Continued

1) Insert the threaded bar (4) through the new bearing and place it in the ear

2) Assemble the

Knurled nut D=80

(F).

3) Assemble the

Press tool D=90

(J).

4) Assemble the

Slide hammer /

Distance (C).

5) Assemble the

Nut M16 (8) xx0900000043

Removal rear shafts Design 1 and 2

The following configuration is used for removal of the rear shafts Design 1 and 2.

Configuration:

• B

• A

• J

• C

• 8

• 4 xx0900000044





481



Continued

1) Assemble the adapter (B) into the shaft.

2) Assemble the threaded bar (4) and the adapter

(B)

3) Assemble the

Press tool D=103


M16.

4) Assemble the

Slide hammer /

Distance (C).


xx0900000045

Refitting rear shafts Design 1

The following configuration is used for refitting of the rear shafts Design 1.

Configuration:

• 4

• F

• G

• C

• 8 xx0900000047





1) Insert the threaded bar (4) through the new bearing.

2) Assemble the

Knurled nut

D=80 (F).

3) Assemble the

Press tool D=110

(G).

4) Assemble the

Slide hammer /

Distance (C).

5) Assemble the

Nut M16 (8).

xx0900000060








483



Continued

Refitting rear shafts Design 2

The following configuration is used for refitting of the rear shafts Design 2.

Configuration:

• 4

• K

• G

• C

• 8

1) Insert the threaded bar (4) through the new bearing.

2) Assemble the

Press tool D=100

(K).

3) Assemble the

Press tool D=110

(G).

4) Assemble the

Slide hammer /

Distance (C).

5) Assemble the

Nut M16 (8) xx0900000049 xx0900000061

484 xx0900000050





7.9 Lifting accessories and lifting instructions

7.9 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.




485


8 Spare parts

8.1 Spare part lists and illustrations

8 Spare parts

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

.




487


9 Circuit diagrams

9.1 Circuit diagrams


9.1 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 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






9.1 Circuit diagrams

Continued

Product


Circuit diagram - IRB 6620 / IRB 6620LX


Circuit diagram - IRB 6650S





Circuit diagram - IRB 910SC


3HAC025090-001

3HAC025090-001

3HAC025744-001

3HAC13347-1

3HAC025744-001

3HAC025744-001

3HAC029940-001

3HAC043446-005

3HAC13347-1

3HAC025744-001

3HAC050778-003

3HAC056159-002




Index

Index

A

Absolute Accuracy, calibration, 441

additional mechanical stop location, 161

air quality, 51

aluminum

disposal, 450

ambient humidity

operation, 65

storage, 64

ambient temperature

operation, 65

storage, 64

assembly instructions, 49

assessment of hazards and risks, 20

B

balancing device bearing, replacement, 297

base plate

guide pins, 81 securing, 81

batteries

disposal, 450

handling, 38

battery

replacing, 188, 287

battery pack

replacing, interval, 123

battery shutdown

service routine, 188, 287

brake release, 78

brake release board, replacement, 293

brakes

testing function, 37

buttons for brake release, 78

C

cabinet lock, 26, 32

cable harness axes 1-6, replacement, 222

cabling, robot, 115

cabling axis 5, replacement, 237

cabling between robot and controller, 115

calibrating

roughly, 444

calibration

Absolute Accuracy type, 440

rough, 444

standard type, 440

when to calibrate, 439

calibration, Absolute Accuracy, 441 calibration manuals, 441

calibration marks, 442

calibration position

jogging to, 447

scales, 442 calibration scales, 442

CalibWare, 440

carbon dioxide extinguisher, 23

cast iron

disposal, 450

changing oil

axis 1, 170

cleaners

approved, 212 requirements, 212

cleaning, 210

climbing on robot, 26

Cold environments, 117

complete arm system, replacement, 240

connecting the robot and controller, cabling, 115

connection

external safety devices, 27

copper

disposal, 450

D

damage to additional mechanical stop, 161

damage to mechanical stop, 159

danger levels, 41

detergents

approved, 212 requirements, 212

dimensions

frame, 92

lower arm, 89

turning disk, 93

upper arm, 91

direction of axes, 443

E

enabling device, 31

environmental information, 450

equipment on robot, 89

ESD

damage elimination, 34 sensitive equipment, 34

expected life, 125

external safety devices, 27

extra equipment

fastener quality, 94

frame, 92

lower arm, 89 robot, 89

turning disk, 93

upper arm, 91

F

fastener quality for extra equipment, 94

fire extinguishing, 23

fitting equipment on robot, 89

fitting fork lift, 70

FlexPendant

jogging to calibration position, 447

MoveAbsJ instruction, 447

updating revolution counters, 445

fork lift, 73

foundation

requirements, 64

frame

dimensions, 92

G gearbox

oil change axis 1, 170

gearboxes

location of, 168

grease

disposal, 450

guide pins, base plate, 81

H hanging




491

Index

installed hanging, 26

hazardous material, 450

height

installed at a height, 26

hold-to-run, 31

HRA, 20

humidity

operation, 65

storage, 64

I

information labels location, 157

inspecting

additional mechanical stop, 161

information labels, 157

mechanical stop, 159

inspecting oil levels

axis-6, 139

axis-5, 136

axis-4, 134

axis-3, 131

axis-2, 129

axis-1, 127

installation

mechanical stop axis 1, 108



installing equipment on robot, 89

instructions for assembly, 49

integrator responsibility, 19

intervals for maintenance, 122

L labels

robot, 43

leak-down test, 214

lifting accessory, 464

lifting robot

with fork lift, 73

with roundslings, 76

lifting upper arm

attachment points for lifting accessory, 273

limitation of liability, 19

Lithium

disposal, 450

loads on foundation, 63

locking screw, 315

lower arm

dimensions, 89

replacement, 281

lubrication

amount in gearboxes, 168 type of lubrication, 168

M magnesium

disposal, 450

maintenance schedule, 122

manually releasing brakes, 78

mechanical stop

axis 1, 108

axis 2, 110

axis 3, 112

mechanical stop location, 159

motion of axes, 67

MoveAbsJ instruction, 447

492

N

nation specific regulations, 19

negative directions, axes, 443

neodymium

disposal, 450

NiCad

disposal, 450

nodular iron

disposal, 450

O oil

amount in gearboxes, 168

disposal, 450

type of oil, 168

oil change

axis 1, 170

safety risks, 39

oil level

gearbox axis-6, 139

gearbox axis-5, 136

gearbox axis-4, 134

gearbox axis-3, 131

gearbox axis-2, 129

gearbox axis-1, 127

operating conditions, 65

P

paint surface damages, 156

pedestal

installed on pedestal, 26

plastic

disposal, 450

positive directions, axes, 443

pressurized components

air quality, 51

Foundry Prime, 50

product standards, 458

protection classes, 65 protection type, 65

protective equipment, 27 protective wear, 27

R

range of movement, 67

region specific regulations, 19

release brakes, 24

repair

painted surface, 156

replacement

bearing, balancing device, 297

brake release board, 293

cable harness axes 1-6, 222

cabling axis 5, 237

complete arm system, 240

lower arm, 281

turning disk, 259

upper arm, 273

wrist unit, 263

replacing

xx, 206, 208

requirements on foundation, 64

responsibility and validity, 19

restricting

working range axis 1, 108






Index revolution counters

storing on FlexPendant, 445

updating, 444

risk of tipping, 69

robot

labels, 43

protection class, 65 protection types, 65

symbols, 43

rubber

disposal, 450

S safety

brake testing, 37

ESD, 34

fire extinguishing, 23

moving robots, 28

release robot axes, 24

signal lamp, 97

signals, 41 signals in manual, 41 symbols, 41

symbols on robot, 43

test run, 29

working range, 30

safety equipment

mechanical stop, 108



signal lamp, 166

safety fence, 20

safety risk

electric parts, 32

hot parts, 35

hydraulic system, 36

installation, 26

oil change, 39

operational disturbance, 26

pneumatic system, 36

service work, 26

voltage, 32

safety signals

in manual, 41

safety standards, 458

safety zones, 20

scales on robot, 442

schedule for maintenance, 122

screw joints, 461

securing

base plate, 81

securing, robot, 86 securing the robot to foundation, attachment screws, 86

sensitive points

Foundry Prime, 53

signal lamp, 97

signals

safety, 41

SMB

replacing, 287

SMB battery

extension of lifetime, 188, 287 replacing, 188, 287

special tools, 466

speed

adjusting, 117

stability, 69




standards, 458

ANSI, 459

CAN, 459

EN, 458

EN IEC, 458

EN ISO, 458

start of robot in cold environments, 117

steel

disposal, 450

storage conditions, 64

symbols

safety, 41

synchronization position, 444

sync marks, 442

system integrator requirements, 19

T temperatures

operation, 65

storage, 64

testing

brakes, 37

three-position enabling device, 31

tightening torque


tools

calibration equipment, Levelmeter, 467

Calibration Pendulum, 468

for service, 466

oil exchange equipment, 468

torques on foundation, 63

transporting the robot, 60 transport support, 60

turning disk dimensions, 93

turning disk replacement, 259

type of motion, 67

U

updating revolution counters, 444

upper arm

dimensions, 91

replacement, 273

V

validity and responsibility, 19

velocity

adjusting, 117

W

weight, 62

balancing device, 304, 306, 322

base plate, 80, 85

gearbox, 423, 428

lower arm, 283–284

motor, 342–343, 358–359

robot, 75–76, 464

upper arm, 277, 279

wrist unit, 266–267

working range, 66

restricting axis 1, 108



wrist unit, replacement, 263

X xx

replacing, 206, 208

493

Index

Z zero position

checking, 447




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 6640 Foundry Prime Product Manual

Product manual

IRB 6640 Foundry Prime

Product manual

IRB 6640 Foundry Prime - 235/2.55

IRB 6640 Foundry Prime - 185/2.8

Table of contents

Overview of this manual

Product documentation

How to read the product manual

Important information about robots with protection type

Foundry Prime

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Decommissioning

7 Reference information

8 Spare parts

9 Circuit diagrams

Index

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