ABB IRB 6620 - 150/2.2 Product Manual

Product manual

Articulated robot

IRB 66 2 0 - 150/2.2

M2004

Product manual

IRB 6620 - 150/2.2

M2004

Document ID: 3HAC027151-001

Revision: B

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, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

Copyright 200 6-2008 ABB All rights reserved.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety 13

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2.3.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2.3.7 Work inside the robot's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.2.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2.3.9 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 29

1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.3.2 DANGER - Moving robots are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.3.4 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 34

1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.3.6 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 Installation and commissioning 37

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.2 Robot transportation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.3 Securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.4.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.4.2 Working range and type of motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.4.3 Risk of tipping / stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.5 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.5.1 Lifting the robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.5.2 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.5.3 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.5.4 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.5.5 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.5.6 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.5.7 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.5.8 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.5.9 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.6 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

2.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

2.6.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.6.3 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3HAC027151-001 Revision: B 3


2.7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2.7.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3 Maintenance 91

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

3.3.2 Inspection, oil level gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

3.3.3 Inspection, oil level gearbox axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100


3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104


3.3.7 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.3.8 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.3.9 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

3.3.10 Inspection, additional mechanical stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3.3.11 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3.3.12 Inspection, signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

3.4 Replacement / changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

3.4.1 Type of oil in gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

3.4.3 Oil change, gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132



3.4.7 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

3.4.8 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3.5 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3.5.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

4 Repair 147

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.3.1 Replacement of cable harness, lower end (axes 1-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.3.2 Replacement of cable harness, upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

4.4.1 Replacement of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

4.4.2 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4.4.3 Replacement of the upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

4.4.4 Replacement of lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

4.5.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

4.5.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

4 3HAC027151-001 Revision: B


4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

4.6.2 Replacement of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203




4.6.6 Replacement of motor, axis 6, IRB 6620/Foundry Plus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

4.7.1 Replacement gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

4.7.2 Replacement gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

4.7.3 Replacement of gearbox axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

4.7.4 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

5 Calibration information 249

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

6 Decommissioning 257

6.1 Environmental information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

7 Reference information 259

7.1 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

7.2 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

7.3 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

7.4 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

7.5 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

7.6 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

7.7 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

8 Spare parts and exploded views 269

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

8.2 Spare parts - cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

8.3 Spare parts - frame and base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

8.4 Spare parts - wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

8.5 Spare parts - Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

8.6 Spare parts - complete robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

9 Circuit diagram 283

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Index 285




Overview

Overview

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.

Usage

This manual should be used during:

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

• maintenance work

• repair work and calibration.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

A maintenance/repair/ installation craftsman 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

Safety

Contents

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

Required information about lifting and installation of the robot.

Installation and commissioning

Maintenance

Repair

Calibration information

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.

3HAC027151-001 Revision: B

Continues on next page

7

Overview

Continued

References

Revisions

Reference

Product specification - IRB 6620

Product manual - IRC5

Operating manual - IRC5 with Flexpendant

Operating manual - Calibration pendulum

Operating manual - Service Information System

Application manual - Additional axes and stand alone controller

Technical reference manual - System parameter

Document Id

3HAC025861-001

3HAC021313-001

3HAC16590-1

3HAC16578-1

3HAC025709-001

3HAC021395-001

Note

3HAC17076-1

Revision

-

A

B

Description

First edition

Changes made in:

• Prerequisites in section Overview

• Oil change in section Maintenance

Changes made in:

• Oil change Shell Tivela S 150 is changed to Kyodo Yushi TMO

150.

• New sections added "Robot transportation precautions" and

"Securing the robot".

• Foundry Plus option added.


Product documentation, M2004

Product documentation, M2004

General

The robot documentation is divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for

M2004 robot systems.

Product manuals

All hardware, robots and controllers, will be delivered with a Product manual that contains:

• Safety information

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

• Maintenance (descriptions of all required preventive maintenance procedures including intervals)

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

• Additional procedures, if any (calibration, decommissioning)

• Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

• Part list

• Foldouts or exploded views

• Circuit diagrams

Technical reference manuals

The following manuals describe the robot software in general and contain relevant reference information:

• RAPID Overview : An overview of the RAPID programming language.

• RAPID Instructions, Functions and Data types : Description and syntax for all

RAPID instructions, functions and data types.

• System parameters : Description of system parameters and configuration workflows.

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, CD with PC software)

• How to use the application

• Examples of how to use the application



9

Product documentation, M2004

Continued

Operating manuals

This group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. The group of manuals includes:

• Emergency safety information

• General safety information

• Getting started, IRC5

• IRC5 with FlexPendant

• RobotStudio

• Introduction to RAPID

• Trouble shooting , for the controller and robot


How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material etc. The references are read as described below.

References to figures

The procedures often include references to components or attachment points located on the robot/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.

Action Note/Illustration

8.

Remove the rear attachment screws, gearbox.

Shown in the figure Location of gearbox on page xx .

References to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, that is article number, dimensions.

The denomination in the procedure for the component or attachment point corresponds to the denomination 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.

Action

3.

Fit a new sealing, axis 2 to the gearbox.

Note/Illustration

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 chapter Safety .


How to read the product manual


1 Safety

1.1. Introduction

1 Safety

1.1. Introduction

Overview

The safety information in this manual is divided in two categories:

• general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information .

• specific safety information, pointed out in the procedure at the moment of the danger.

How to avoid and eliminate the danger is either detailed directly in the procedure, or

further detailed in separate instructions, found in section Safety related instructions on page 30

.


1 Safety

1.2.1. Safety in the robot system

1.2 General safety information

1.2.1. Safety in the robot system

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. 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.

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, for example:

• Operating Manual - IRC5 with FlexPendant (M2004)

• Product Manual

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. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

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.

Related information

Type of information Detailed in document

Installation of safety devices

Changing operating modes

Restricting the working space

Section

Product manual for the robot Installation and commissioning

Operating manual - IRC5 with

FlexPendant

(RobotWare 5.0)

Operating modes

Product manual for the robot Installation and commissioning


1 Safety

1.2.2.1. Safety risks during installation and service work on robot

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on robot

Overview

This section includes information of general safety risks to be considered when performing installation and service work on the robot.

General risks during installation and service

• The instructions in the Product Manual, chapter Installation and Commissioning must always be followed.

• Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly.

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

• Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.

Non-voltage related risks

• 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.

• The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm.

• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, are dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.

• Be aware of stored heat energy in the controller.

• Never use the robot as a ladder, that is, do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system

• 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.



1 Safety

1.2.2.1. Safety risks during installation and service work on robot

Continued

Complete robot

Safety risk

Hot components!

Description

Removed parts may result in collapse of robot!

CAUTION!

Motors and gears are HOT after running the robot!

Touching motors and gears may result in burns!

With higher environment temperature more surfaces on the robot are getting HOT and may result in burns too!

WARNING!

Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Cabling

Safety risk

Cable packs are sensitive to mechanical damage!

Description

CAUTION!

The cable packs are sensitive to mechanical damage!

They must be handled with care, especially the connectors, in order to avoid damaging them!

Gearboxes and motors

Safety risk

Gears may be damaged if excessive force is used!

Description

CAUTION!

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!


1 Safety

1.2.2.2. Safety risks related to tools/workpieces

1.2.2.2. Safety risks related to tools/workpieces

Safe handling

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

Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.

CAUTION!

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


1 Safety

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

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

• The pressure in pneumatic and hydraulic systems must be released before starting to repair them.

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

1.2.2.4. Safety risks during operational disturbances

1.2.2.4. Safety risks during operational disturbances

General

• The industrial robot is a flexible tool which can be used in many different industrial applications.

• All work must be carried out professionally and in accordance with the applicable safety regulations.

• Care must be taken at all times.

Qualified personnel

• 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.

Extraordinary risks

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.


1 Safety

1.2.2.5. Risks associated with live electric parts

1.2.2.5. Risks associated with live electric parts

Voltage related risks, general

• 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 mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

• The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.

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 mains supply/mains switch

• The transformers

• The power unit

• The control power supply (230 VAC)

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

• The drive unit (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 high 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, see chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the

OFFposition. Power supply cables which are in motion during the working process may be damaged.


1 Safety

1.2.3.1. Safety fence dimensions

1.2.3. Safety actions

1.2.3.1. Safety fence dimensions

General

Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning

Dimension the fence or enclosure to enable it 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 Product Specification - Description, Robot Motion ).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.


1 Safety

1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the robot system (robot or controller)!


1 Safety

1.2.3.3. Emergency release of the robot’s arm

1.2.3.3. Emergency release of the robot’s arm

Description

In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot.

How to release the brakes is detailed in section:

•

Manually releasing the brakes on page 61

The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar.

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!


1 Safety

1.2.3.4. Brake testing

1.2.3.4. Brake testing

When to test

During operation the holding brake of each axis motor wear normally. A test may 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 checked as detailed below:

1.

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

2.

Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller.

3.

Check 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.


1 Safety

1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!

Do not change "Transm gear ratio" or other kinematic system parameters from the

FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".


1 Safety

1.2.3.6. Safe use of the FlexPendant

1.2.3.6. Safe use of the FlexPendant

NOTE!

The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

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

• The enabling device must never be rendered inoperative 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.

• The programmer must always bring the FlexPendant with him/her, when entering the robot's working space. This is to prevent anyone else taking control of the robot without the programmer knowing.

Enabling device

The 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 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, robot operation is impossible.

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 is detailed in Operating manual - IRC5 with

FlexPendant .


1.2.3.7. Work inside the robot's working range

1 Safety

1.2.3.7. Work inside the robot's working range

WARNING!

If work must be carried out within the robot’s work envelope, the following points must be observed:

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

• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in 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.

• Pay attention to the rotating axes of the robot! Keep a distance to the axes in order not to 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.

• Test the motor brake on each axis, according to section

Brake testing on page 24 .


1 Safety

1.2.3.8. Signal lamp (optional)

1.2.3.8. Signal lamp (optional)

Description

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

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 controller documentation.


1 Safety

1.2.3.9. Translate the information on safety and information labels

1.2.3.9. Translate the information on safety and information labels

Labels on the product

Both the robot 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 system, for example during installation, service or operation.

Translation possibilities

The labels fitted to the product contain space for adding a fourth language underneath the three standard languages (English, German and French).

Add a local language to the label by:

• Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

Example of transparent sticker

The figure below shows the location of the free space on one of the labels on the robot, where the fourth language can be added. The figure also shows a transparent sticker, containing the text in Swedish.

xx0500002517

A Free space for adding a fourth language


1 Safety

1.3.1. Safety signals, general

1.3 Safety related instructions

1.3.1. Safety signals, general

General

This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting 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.

• An instruction of how to eliminate the danger to facilitate performing the activity at hand.

Danger levels

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

Symbol danger warning

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Signification

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 etc.

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.

The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.

Electrical shock

CAUTION 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.

30



Symbol

1 Safety

1.3.1. Safety signals, general

Continued

Designation Signification

ELECTROSTATIC

DISCHARGE (ESD)

The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.

Electrostatic discharge

(ESD)

NOTE Note symbols alert you to important facts and conditions.

Note

TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Tip


1 Safety

1.3.2. DANGER - Moving robots are potentially lethal!

1.3.2. DANGER - Moving robots are potentially lethal!

Description

Any moving robot is a potentially lethal machine.

When running the robot, it 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.

Elimination

Action Note

1. 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.

2. Usually the hold-to-run function is active only in manual full speed mode. To increase safety it is also possible to activate hold-to-run for manual reduced speed with a system parameter.

The hold-to-run function is used in manual mode, not in automatic mode.

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

How to use the hold-to-run function in

RobotWare 5.0 is detailed in section How to use the hold-to-run function in the

Operating manual - IRC5 with FlexPendant .


1 Safety

1.3.3. DANGER - First test run may cause injury or damage!

1.3.3. DANGER - First test run may cause injury or damage!

Description

Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run.

Elimination

Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):

Action

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

2. Install all safety equipment properly!

3. Make sure all personnel are standing at a safe distance from the robot, that is out of its reach behind safety fences, etc!

4. Pay special attention to the function of the part previously serviced!


1 Safety

1.3.4. WARNING - The brake release buttons may be jammed after service work

1.3.4. WARNING - The brake release buttons may be jammed after service work

Description

The brake release unit has push buttons for 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.

In case 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

To eliminate the danger after service work has been performed inside the SMB recess, follow the procedure below.

Action

1. Make sure the power is turned off.

2. Remove the push button guard, if necessary.

3. Check the push buttons of the brake release unit by pressing them down, one by one.

Make sure none of the buttons are jammed in the tube.

4. 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!


1 Safety

1.3.5. WARNING - The unit is sensitive to ESD!

1.3.5. WARNING - 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.

Elimination

Action Note

1. Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

2. Use an ESD protective floor mat.

The mat must be grounded through a currentlimiting resistor.

3. Use a dissipative table mat.

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

Location of wrist strap button

The wrist strap button is located in the right corner as shown in the illustration below.

xx0500002171

A Wrist strap button


1 Safety

1.3.6. WARNING - Safety risks during work with gearbox oil

1.3.6. WARNING - Safety risks during work with gearbox oil

Description

When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes!

Warnings and elimination

Warning Description Elimination / Action

Changing and draining gearbox oil may require handling hot oil of up to 90 °C!

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

-

Hot oil!

When opening the oil plug, there may be pressure present in the gearbox, causing oil to spray from the opening!

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

-

Possible pressure build up in gearbox!

-

Do not overfill!

-

Do not mix types of oil!

Overfilling of gearbox oil 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 with oil!

After filling, check the correct oil level.

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 instruction.

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

After refilling, check the oil level.


2 Installation and commissioning

2.1. Introduction



General

This chapter contains information for installing the robot to the working site.

More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), can be found in the Product specification for the robot.



2.2. Robot transportation precautions

2.2. Robot transportation precautions

General

This section details ABB approved transportation precautions for ABB robots.

CAUTION!

All transportation in or outside the plant, must be carried out according to description in method 1.

If transportation according to method 1 is not possible, use method 2.

Transportation in any other way than method 1 or 2 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

Transportation according to method 1 is strongly recommended by ABB.

38 xx0800000030



Method 2



Continued

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, detailed in section

Risk of tipping / stability on page 53 .

• Always read and follow the instructions in section

Pre-installation procedure on page

47

Transportation according to method 2 is approved by ABB, if use of method 1 is not possible.

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

•

Always read and follow the instructions in section Securing the robot on page 45

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

Transport position with a transport support on page 42

.

•

Always use the recommended transport support detailed in sub section Recommended transport support on page 43

.



39



Continued

IRB7600/IRB66XX

40 xx0800000037

A

B

C

D

Transport Support

Hexagon socket head cap screw M16x140

Threaded bar M10x200

Nut M10



IRB6620/Foundry Plus



Continued xx0800000036

C

D

A

B

Transport Support

Hexagon socket head cap screw M10x50

Threaded bar M10x280

Nut M10



41



Continued

Transport position with a transport support

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

IRB 6620/Foundy Plus

42 xx0800000041





Continued

Recommended transport support

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

IRB 7600/IRB 66XX xx0800000039



43



Continued

IRB 6620

44 xx0800000038



2.3. Securing the robot

2.3. Securing the robot

General

This section describes how to secure the robot using the transport support.

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.

Securing the robot xx0800000062

Action Note

1. Mount the transport support lower end to the robot using the recommended screw joint, (A) in figure.

Do not tightening the screw.

See attachment point for the specific

robot in section Transport position with a transport support on page 42

.



45


2.3. Securing the robot

Continued

Action Note

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

Transport position with a transport support on page 42

.

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 section Manually releasing the brakes on page 61 .

See attachment point for the specific

robot in section Transport position with a transport support on page 42

4. Tightening all the attachment screws (A) and

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

CAUTION!

Do not attempt to tightening any attachment screw without first release 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 section




2.4.1. Pre-installation procedure

2.4 Unpacking

2.4.1. Pre-installation procedure

General

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.

Checking the pre-requisites for installation

The checklist below details what must be observed before proceeding with the actual installation of the robot:

Action

1. Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation.

2. Visually inspect the robot to make sure it is not damaged.

3. Make sure the lifting device used is suitable to handle the weight of the robot as specified in

Weight, robot on page 47 .

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

Storage conditions, robot on page 48

.

5. Make sure the expected operating environment of the robot conforms to the specifica-

tions as described in Operating conditions, robot on page 48 .

6. Before taking the robot to its installation site, make sure the site conforms to

Loads on foundation, robot on page 47 ,

Requirements, foundation on page 48 and Protection classes, robot on page 48 .

7. Before moving the robot, please observe

Risk of tipping / stability on page 53 regarding

risk of tipping!

8. When these prerequisites are met, the robot may be taken to its installation site as described in section: On-site installation .

Weight, robot

The table below shows the weights of the different models:

Robot model

IRB 6620 - 150/2.2

* Weight of robot excluding DressPack.

Weight

900 kg *

Loads on foundation, robot

The table below shows the various forces and torques working on the foundation during different kinds of operation, in relation to the base coordinate system.

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!

Force

Force xy

Force z

Endurance load (operation)

± 7.3 kN

11.0 ±2.0 kN

Max. load (emergency stop)

± 15.5 kN

11.0 ±3.7 kN



47


2.4.1. Pre-installation procedure

Continued

Force

Torque xy

Endurance load (operation)

± 19.0 kNm

± 18.0 kNm*

± 4.4 kNm Torque z

* When using base spacers (option 571-1).

Max. load (emergency stop)

± 32.5 kNm

± 37.2 kNm*

± 10.4 kNm

Requirements, foundation

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

Requirement Value Note

Min. levelity

Max. tilt

0.5 mm

15° The limit for the maximum load on the robot is reduced if the robot is tilted.

Contact ABB for further information about acceptable loads.

Min. resonance frequency 22 Hz

Storage conditions, robot

The table below shows the allowed storage conditions for the robot:

Parameter

Min. ambient temperature

Max. ambient temperature

Max. ambient temperature (less than 24 hrs)

Max. ambient humidity

Value

-25° C

+55° C

+70° C

Max. 95% at constant temperature

Operating conditions, robot

The table below shows the allowed operating conditions for the robot:

Parameter

Min. ambient temperature

Max. ambient temperature

Max. ambient humidity

Value

+5° C

+50° C

Max. 95% at constant temperature

Protection classes, robot

The table below shows the protection class of the robot:

Equipment Protection class

Robot

Upper arm, including wrist

IP 54

IP 67



2.4.2. Working range and type of motion

2.4.2. Working range and type of motion

Working range

The following figures show the working ranges of the robot model mounted in different ways.

The extreme positions of the robot arm are specified at the wrist center (dimensions in mm).

Floor mounted

The illustration below shows the unrestricted working range when the robot is floor mounted: xx0600002906



49



Continued

Suspended mounted

The illustration below shows the unrestricted working range when the robot is mounted suspended: xx0600002907

50





Continued

Floor mounted in 15° angle

The illustration below shows the unrestricted working range when the robot is floor mounted in 15° angle: xx0600002908

A

B

Note ! Maximum tilt angle is 15°

Intersection between base and axis 1 center



51



Continued

Turning radius - floor mounted

The turning radius for the robot when floor mounted, is shown in the figure below.

Type of motion xx0600002909

Axis Type of motion

3

4

1

2

5

6

Rotation motion

Arm motion

Arm motion

Wrist motion

Bend motion

Turn motion

Range of movement Note

+ 170° to - 170°

+ 140° to - 65°

+ 70° to - 115°

+ 300° to - 300°

Limitations with dresspack

+ 130° to - 130° Limitations with dresspack

+ 300° to - 300° default Max. ±96 revolutions ¹

¹ The default working range can be extended by changing parameter values in the software.

Option Advanced Motion is required.



2.4.3. Risk of tipping / stability

2.4.3. Risk of tipping / stability

Risk of tipping

When the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over.

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

Stabililty

The figure below shows the robot in its shipping position, which also is its most stable position. xx0600002935

WARNING!

The robot is likely to be mechanically unstable while not secured to the foundation!



2.5.1. Lifting the robot with fork lift

2.5 On-site installation

2.5.1. Lifting the robot with fork lift

General

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

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

Fork lift device set

The fork lift device set, is fitted to the robot as shown in the figure below.

Required equipment xx0600002910

A

B

Fork lift pocket

Attachment screw M20x50 quality 8.8 (2 pcs x 4)

Equipment, etc

Fork lift device set

Standard toolkit

Art. no.

-

3HAC025040-003

Note

The content is defined in section

Standard toolkit on page 265

.

54





Continued

Lifting the robot with fork lift

The procedure below details how to secure the fork lift set in order to lift the robot and move it using fork lift ONLY!

The illustration below shows the position of the robot when lifting it with fork lift.

xx0600002911

Action Note

1. Move the robot to the position as shown in the figure above!

Release the brakes if required as detailed

in section Manually releasing the brakes on page 61 .

2.

NOTE!

No load is permitted on the robot!

DANGER!

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!



55



Continued

Action

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

Note

Make sure the original screws are always used (or replacements of equivalent quality: M20x50, quality 8.8)!

Attachment points on the robot are shown in the figure below.

56

4. Double check that all four fork lift pockets are properly secured before lifting.

xx0600002927

• A: Attachment holes for fork lift xx0600002930

• A: Fork lift pocket

• B: Attachment screw M20x50 quality 8.8 (2 pcs x 4). Tightening torque : 300 Nm





Continued

Action

5. Insert the fork lift forks into the pockets.

6.

Note

CAUTION!

The robot weighs 900 kg! All lifting equipment used must be sized accordingly!

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

8.

NOTE!

Move the robot with low speed!

WARNING!

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



2.5.2. Lifting robot with roundslings

2.5.2. Lifting robot with roundslings

General

The robot may be lifted with roundslings according to the illustration below. The illustration is identical with the label attached to the robot’s lower arm.

Attachment points

The figure below shows how to attach the roundslings to the robot. xx0600002921

A

B

C

D

E

Roundsling upper arm, 2.5 m.

Roundsling upper arm, 2 m.

Roundsling robot, 2,5 m (4 pcs).

Lifting eye, M20 (4 pcs)

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

Sling specification

Sling type

Roundsling, robot

Qty

4 pcs

Lifting capacity

1 000 kg

Length / Note

2.5 m

58





Continued

Sling type

Roundsling, upper arm

Roundsling, upper arm

Qty

2 pcs

1 pc

Lifting capacity

1 000 kg

1 000 kg

Length / Note

Note!

Do not stretch!

2 m

Secures against rotation.

2 m

Note!

Do not stretch!

Secures against rotation.

Lifting with roundslings

Action

1. Attach the roundslings to the robot according to the figure

Attachment points on page 58

.

Note

NOTE!

For Cleanroom robots it is important to apply the roundslings:

• between robot harness and lower arm

• behind the side bracket, balancing cylinder.

2. Attach the lifting eye bolts in the rear M20 holes. Shown in figure

Attachment points on page 58

.

3.

NOTE!

Make sure that the roundslings do not lie against sensitive parts, for example harness and customer equipment!

4. When attaching the roundsling A on the upper arm, put it in a U-shape through the hole in the wrist.

5. When attaching the roundsling B on the upper arm, put it in a sling around the gearbox axis 4 and on the inside of motor axis 4.

Shown in the figure

on page 58 .

Shown in the figure

on page 58 .

Attachment points

Attachment points

6. When attaching the roundsling C , note that it shall be routed on the inside of the cable harness of motor axis 2, in order not to damage the harness!

Shown in the figure

Attachment points on page 58 .

7.

CAUTION!

The robot weighs 900 kg! All lifting equipment used must be sized accordingly!



59



Continued

8.

Action

WARNING!

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

Note



2.5.3. Manually releasing the brakes

2.5.3. Manually releasing the brakes

General

This section details how to release the holding brakes of each axis motor.

Location of brake release unit

The internal brake release unit is located at the frame, as shown in the figure below.

xx0600002936

A Internal brake release unit with push buttons.

Releasing the brakes

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

Action Note

1. The internal brake release unit is located on the frame beside motor axis 1.

The internal brake release unit is equipped with six 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 section

Supplying power to connector R1.MP on page 62 .

The buttons are shown in

the figure Location of brake release unit on page 61 .

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 the robot arm!

3. Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release panel and keeping it depressed.

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



61


2.5.3. 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 in the robot base in order to enable the brake release buttons on the robot.

Note

1.

Action

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



2.5.4. Lifting the base plate

2.5.4. Lifting the base plate

Required equipment

Equipment

Lifting eye, M16

Lifting slings

Hole configuration

Art. no.

3HAC14457-4

Note

3 pcs

3 pcs

Length: approx. 2 m xx0200000096

A Attachment holes for lifting eyes (x3)

Lifting, base plate

1.

Action Note

CAUTION!

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

2. Fit the lifting eyes in the three lifting holes.

3. Fit the lifting slings to the eyes and to the lifting device.

Shown in the figure

Hole configuration on page 63 .



2.5.5. Securing the base plate

2.5.5. Securing the base plate

General

This section details how to secure the base plate.

Base plate, dimensions

64 xx0100000105






A Four holes for alternative clamping, 4x Ø18



65



Continued

Base plate, grooves and holes

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

xx0300000045

A

B

C

Guide sleeve holes (2 pcs)

Orienting grooves (3 pcs)

Levelling bolts, attachment holes (4 pcs)


Equipment Art. no. Note

Base plate

Standard toolkit

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

3HAC12937-9 Includes

• guide sleeves, 3HAC12937-3

• levelling screws, 9ADA120-79

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

A drawing of the base plate itself may be ordered from ABB Robotics!

- The content is defined in section


.

These procedures include references to the tools required.

66





Continued

Recommendations, quality

The table specifies any recommendations made by ABB:

Variable Recommendation

Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm

Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10 mm steel bars, distance 140 mm, class K25, t=250

Recommended bolt quality and dimension

Hilti HDA-P, M20 x 250/50 (maximum thickness of base plate = 50 mm)

Hilti HDA-P, M20 x 250/100 (maximum thickness of base plate = 100 mm)

Base plate

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

Action

1. Make sure the foundation is level.

2.

Note

CAUTION!

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

3. Orient the base plate in relation to the robot work location using the three grooves in the base plate.

Shown in the figure Base plate, grooves and holes on page 66

.

4. Lift the base plate to its mounting position. Detailed in section

Lifting the base plate on page 63 .

5. Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension.

If possible, observe the recommendations specified in section

Recommendations, quality on page 67 . ABB does not

assume any responsibility for other foundation qualities, due to great variations in the foundation properties.

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

Shown in the figure Base plate, grooves and holes on page 66

.

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

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

9. Recheck the four robot contact surfaces on the base plate to make sure they are level and flat.

If they are not, pieces of sheet metal or similar may be used to bring the base plate to a level position.

Maximum allowed deviation: 0.5 mm



2.5.6. Orienting and securing the robot

2.5.6. 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. The requirements made on the foundations are shown in the following tables and figures.

Illustration, robot fitted to base plate

The illustration below 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: M24 x 100

Quality: Quality 8.8

Suitable washer:

Tightening torque:

Thickness: 4 mm

Outer diameter: 44 mm

Inner diameter: 25 mm

725 Nm

68





Continued

Securing the robot

The procedure below details how to secure the robot to the base plate after fitting the plate to the foundation.

Action Note

1. Lift the robot.

2. Move the robot to the vicinity of its installation location.

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

Detailed in section

Lifting robot with roundslings on page 58

.

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

5. Fit the bolts and washers in the base attachment holes.

NOTE!

One of the guide sleeve holes is elongated!

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

Specified in Attachment screws on page 68 .

Shown in the figure

Illustration, robot fitted to base plate on page 68 .

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

NOTE!

Lightly lubricate the screws before assembly!



69



Continued

Hole configuration, base

The illustration below shows the hole configuration used when securing the robot.

xx0600002932

Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes.

70 xx0600002934



2.5.7. Suspended mounting

2.5.7. Suspended mounting

General

Initially the system is configured for mounting on the floor, without leaning. The method for mounting the robot in a suspended position is basically the same as for floor mounting.

NOTE!

With suspended installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved.

System parameters

If the robot is mounted at any other angle, the system parameter “gravity beta” must be updated. Gravity beta specifies the robot’s mounting angle expressed in radians.

NOTE!

It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will result in:

• Overloading the mechanical structure.

• Lower path performance and path accuracy.

• Some functions will not work properly: for example Load Identification & Collision detection.



71



Continued

Mounting angles and values

The parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated in the following way for a mounting angle of 15°.

Gravity beta = 15° x 3.141593/180 = 0.261799 radians.

Example of position Mounting angle

Floor (A)

Tilted (B)

Suspended (C)

0°

15°

180°

Gravity beta

0.000000 (Default)

0.261799

3.141593

72 xx0600003144

A

B

C

Floor mounted

Tilted mounting, mounting angle 15°.

Suspended mounting, mounting angle 180°.





Continued

Defining the parameter

The value of the system parameter Gravity beta must be redefined when changing the mounting angle of the robot. The parameter belongs to the type Robot , in the topic Motion .

How to calculate a new value is detailed in Mounting angles and values on page 72

.

The parameter is further detailed in the Technical reference manual - System parameters .

The parameter can be edited either with the FlexPendant or in RobotStudio. Read about how to change the parameter in the Operating manual - IRC5 with FlexPendant or in the

Operating manual - RobotStudio . Article numbers for the manuals are specified in

References on page 8

.



2.5.8. Fitting equipment on robot

2.5.8. Fitting equipment on robot

General

The robot features mounting holes for additional equipment.

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

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 lower arm when fitting extra equipment.

Always use appropriate attachment screws!

74 xx0600002940








75



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.

76 xx0600002941








77



Continued

Illustration, fitting of extra equipment on frame

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

78 xx0600002947








79



Continued

Illustration, fitting on turning disk

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

80 xx0200000397

Turning disk for robot version IRB6620 - 150/2.2. Use every other of the bolt holes for six attachment bolts, as numbered in the figure.






Fastener quality

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

12.9. When fitting other equipment standard screws with quality 8.8 may be used.



2.5.9. Loads

2.5.9. Loads

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!

Incorrect defined loads may result in operational stops or major damage on the robot.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the

Product Specification . The loads must also be defined in the software as detailed in Operating manual IRC5 with FlexPendant .

Stop time and braking distances

Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB.



2.6.1. Introduction

2.6 Restricting the working range

2.6.1. Introduction

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.

• Axis 3, hardware (mechanical stop) and software.

As a standard configuration, axis 1 is allowed to move ±170°.

This section describes how to install hardware that restricts the working range.

Notice that adjustments must also be made in the software. References to software manuals are given in the following installation procedures.



2.6.2. Mechanically restricting the working range of axis 1

2.6.2. Mechanically restricting the working range of axis 1

General

The working range of axis 1 is limited by fixed mechanical stops and 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 below shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1.

84 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.

Art. no.

Note

Movable mechanical stop set, axis 1

(+15°/-7.5°)

Movable mechanical stop set, axis 1

(+7.5°/-15°)

Standard toolkit

Technical reference manual - System parameters (RobotWare 5.0)

-

-

3HAC025204-003 Includes:

• two stops (+15°/ -7.5°),

3HAC025366-001

• two stops (+7.5°/ -15°),

3HAC025367-001

• attachment screws and washers

• document for movable mech.stop,

3HAC025408-001


• two stops (+15°/ -7.5°),

3HAC025366-001

• two stops (+7.5°/ -15°),

3HAC025367-001

• attachment screws and washers

• document for movable mech.stop,

3HAC025408-001

The content is defined in

section Standard toolkit on page 265 .

Installation, mechanical stops axis 1

The procedure below details how to fit the mechanical stops of axis 1 to the robot. An assembly drawing is also enclosed with the product.

Note

1.

Action

DANGER!


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

Mechanical stops, axis 1 on page 84 .

Tightening torque: 120 Nm.



85



Continued

Action Note

3.

NOTE!

To utilize the option 561-1 "Extended working range axis 1" the software working range limitations must be re-defined. The motion configuration parameter "arm/rob1_1/Upper

Joint Bound" and "arm/rob1_1/Lower Joint

Bound" must be changed to 3.84 resp. -3.84.

The values are in radians that is 220 deg. =

3.84 rad.

The system parameters that must be changed in RobotWare 5.0 (Upper joint bound and Lower joint bound) are further detailed in Technical reference manual -

System parameters .

4.

WARNING!

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




2.6.3. Mechanically restricting the working range of axis 3

General

The working range of axis 3 is limited by a fixed mechanical stop. This stop limits the backwards movement of the upper arm to -90°, which secures the robot arm from tipping over.

Mechanical stops, axis 3

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

xx0600002939

A

B

Mechanical stop pin, axis 3

Attachment screw plus washer


Equipment, etc.

Mechanical stop set, axis 3

Art. no.

3HAC025290-003

Standard toolkit

Technical reference manual -

System parameters

(RobotWare 5.0)

-

-

Note

Includes:

• one mechanical stop pin,

3HAC025092-001.

• attachment screw and washer.

• document for Mech stop pin, 3HAC025409-001.


Standard toolkit on page 265 .

Art. no. is specified in section

References .



87



Continued

Installation, mechanical stops axis 3

The procedure below details how to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product.

Note

1.

Action

DANGER!


2. Fit and tighten the mechanical stop, axis 3, on to the lower arm.

Shown in the figure Mechanical stops, axis 3 on page 87

3.

NOTE!

The software working range limitations must be re-defined to correspond to the changes in the mechanical limitations of the working range(+70°/ -90°).

The system parameters that must be changed in RobotWare 5.0 (Upper joint bound and Lower joint bound) are further detailed in Technical reference manual -

System parameters .

4.

WARNING!

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



2.7.1. Robot cabling and connection points

2.7 Electrical connections

2.7.1. Robot cabling and connection points

General

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 Description

Robot cables 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 89

.

Customer cables (option) Handles communication with equipment fitted on the robot by the customer, including databus communication, low voltage signals and high voltage power supply + protective ground.

See the product manual for the controller

1)

.

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)

1)

.

1)

Art. no. is specified in section References on page 8 .

The cable categories are divided into sub-categories, specified below:

Robot cables

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

Cable sub-category Description

Robot cable, power

Robot cable, signals

Connection point, cabinet

Connection point, robot

R1.MP 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 R1.SMB

Robot cable, power

Cable

Robot cable, power, 7 m




Art. no.

3HAC11818-1

3HAC11818-2

3HAC11818-3

3HAC11818-4



89


2.7.1. 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


3 Maintenance

3.1. Introduction

3 Maintenance


Structure of this chapter

This chapter details all maintenance activities recommended for the robot and any external units of the robot.

It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

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

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


Before any service 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 describe danger and safety risks when performing the procedures. Read the chapter Safety before performing any service work.


3 Maintenance

3.2.1. Specification of maintenance intervals

3.2 Maintenance schedule and expected component life

3.2.1. Specification of maintenance intervals

Description

The intervals is specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot:

• Calendar time: specified in months regardless of whether the robot system is run or not

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


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 section

Expected component life on page 95

Robot overhaul

Overhaul of the robot is recomended after 8 years, see expected component life specified in

section Expected component life on page 95

Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals:

Maintenance activity

Cleaning

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Changing

Changing

Equipment Interval Detailed in section

Robot

Axis 1 gear, oil level






Robot harness

Damper axes 2-5

-

12 mths

12 mths

12 mths

12 mths

12 mths

12 mths

12 mths

Information labels 12 mths

12 mths

1)

1)

1)

1)

Cleaning, robot on page 145

Inspection, oil level gearbox axis 1 on page 96




Inspection, oil level, gearbox axis 5 on page 104


Inspection, cable harness

Inspection, information labels on page 111

Inspection, damper axes 2-5 on page 118

Mechanical stop, axis 1

12 mths

Inspection, mechanical stop, axis 1 on page 113

Axis 1 gear oil:

Kyodo Yushi TMO

150

First change after: 6

000 h

Second change after:

24 000 h 9)

Do not mix with other oils!

Oil change, gearbox axis 1 on page 126

Axis 2 gear oil:

Kyodo Yushi TMO

150


000 h


24 000 h 9)





93

3 Maintenance

3.2.2. Maintenance schedule

Continued


Changing

Changing

Changing

Changing

Replacement

Replacement

Equipment Interval Detailed in section

Axis 3 gear oil:

Kyodo Yushi TMO

150

Axis 4 gear oil:

Mobilgear 600

XP320


000 h


24 000 h 9)

24 000 h

1)


Oil change, gearbox, axis 3 on page 132


Axis 5 gear oil :

Mobilgear 600

XP320

24 000 h 1)


Axis 6 gear oil:

Kyodo Yushi TMO

150

Robot harness


000 h


24 000 h 9)

See note below

3)



Replacement of cable harness, lower end (axes 1-

2) on page 153

Replacement of cable harness, upper end on page

159

SMB Battery pack When necessary

10)

Replacement of SMB battery on page 142

•

•

• 3)

Replace when damage is detected or when approaching life limit as specified in

Expected component life on page 95

.

9)

"24 000 h" = 6000 h + 18000 h.

10)

The lithium battery is used as a memory back-up when the robot system is switched off. Therefore, the life of a lithium battery depends on how frequently the power to the system is switched off, and also if the environment temperature is higher than recommended operating temperature. The life time of the battery pac can also be extended if the battery shutdown service routine is used during longer production breaks, described in Operating manual – IRC5 with FlexPendant, chapter battery shutdown service rutine. The consumption in ordinary shutdowns is then approx. 1 mA. Using sleep mode the consumption is reduced to 0,3 mA. When the battery is nearly discharged, less then 3 Ah left an alert is given on the FlexPendant and the battery should be replaced before next longer power switched off period

Activities and intervals, optional equipment

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


Inspection

Inspection

Equipment

Signal lamp

Interval Detailed in section

Inspection, signal lamp on page 120

Mechanical stop axis 1 and 3 12 mths


3 Maintenance

3.2.3. Expected component life

3.2.3. Expected component life

General

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

Expected life

Component

Cabling for robot, 7th axis

Expected life

4,000,000 cycles axis 1 ±180º

2,000,000 cycles axis 1 ±220º

40,000h

Note

See note 1)

Gearbox See note 3)

1)

The expected life can also be affected by assemblage of cabling other than standard options.

The given life is based on a test cycle that for every axis starts from the calibration position to minimum angle to maximum angle and back to the calibration position. Deviations from this cycle will result in differences in expected life! The life may also be affected by acid or alkaline environment.

3)

The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal application. Depending on the actual application, the life of individual gearboxes may vary greatly from this specification. The Service Information System (SIS), integrated in the robot software, keeps track of the gearbox life in each individual case and will notify the user when a service is due.

The SIS for an M2004 system is described in the Operating manual - Service Information

System . Document number can be found in section

References on page 8 .


3 Maintenance

3.3.1. Inspection, oil level gearbox axis 1

3.3 Inspection activities

3.3.1. Inspection, oil level gearbox axis 1

Location of gearbox

The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the figure below. xx0600002958

A

B

C

Oil plug, filling

Oil plug, inspection

Oil plug, draining


Equipment

Lubricating oil

Standard toolkit


-

Art. no.

3HAC032140-001

Note

Kyodo Yushi TMO 150

Note!

Do not mix with other oil types!



.


Inspection, oil level gearbox, axis 1

The procedure below details how to inspect the oil level in gearbox axis 1.

Note

1.

Action

WARNING!

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

WARNING - Safety risks during work with gearbox oil on page 36

.

96



3 Maintenance


Continued

Note

2.

Action

DANGER!


3. Open the oil plug, inspection.

Shown in the figure Location of gearbox on page 96 .

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

5. Add oil if required.

6. Refit the oil plug, inspection.

Art. no. is specified in Required equipment on page 96

.

Further information about how to fill

the oil may be found in section Filling oil, axis 1 on page 127 .



3 Maintenance



Location of gearbox, floor mounted

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

The figure below shows the robot floormounted.

xx0600002959

A

B

C

Oil plug, filling


Oil plug, draining

Location of gearbox, suspended

The figure below shows the robot mounted suspended.

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

98 xx0600002960

A

B

C

Oil plug, filling


Oil plug, draining



3 Maintenance


Continued


Equipment etc.

Lubricating oil

Standard toolkit

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

-

Art. no.

3HAC032140-001

Note

Kyodo Yushi TMO 150

Note! Do not mix with other oil types!



.


Inspection, oil level gearbox 2


Note

1.

Action

2.

WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please observe the

safety information in section WARNING - Safety risks during work with gearbox oil on page 36 .

DANGER!


3. Open the oil plug, filling. Shown in the figure

Location of gearbox, floor mounted on page 98 .

4. Measure the oil level at the oil plug, filling.

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

Shown in the figure

Location of gearbox, floor mounted on page 98 .


6. Refit the oil plug, filling.

Art. no. is specified in

Required equipment on page 99 .

Filling of oil is detailed further in

section Filling, oil on page 130

.



3 Maintenance




The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0600002961

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit


-

Art. no.

3HAC032140-001

Note

Kyodo Yushi TMO 150

Note!





100



3 Maintenance


Continued


The procedure below details how to inspect the oil level in the gearbox axis 3.

Note

1.

Action

WARNING!



.

2. Move the robot to the calibration position. Detailed in section

Calibration scales and correct axis position on page

252 .

3.

DANGER!


4. Open the oil plug, filling.

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


Shown in the figure

Location of gearbox on page 100 .

Art. no. is specified in Required equipment on page 100 .

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

Filling, oil on page 133

.

7. Refit the oil plug, filling. Tightening torque: 24 Nm.


3 Maintenance




The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0600002962

A

B

Oil plug, filling / inspection

Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit


Art. no.

-

11712016-604

Note

Mobilgear 600 XP320



.




Note

1.

Action

WARNING!


WARNING -

Safety risks during work with gearbox oil on page 36

.

102



3 Maintenance


Continued

Action

2. Move the robot to the calibration position.

3.

Note

Shown in section Calibration scales and correct axis position on page 252 .

DANGER!



Shown in the figure


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


7. Refit the oil plug.


Required equipment on page 102

.

Further information about how to fill the

oil may be found in section Filling, oil on page 136 .



3 Maintenance

3.3.5. Inspection, oil level, gearbox axis 5

3.3.5. Inspection, oil level, gearbox axis 5


The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0600002963

A

B


Oil plug, draining


Equipment etc.

Lubricating oil

Standard toolkit


Art. no.

-

11712016-604

Note

Mobilgear 600 XP320






Note

1.

Action

WARNING!

Handling gearbox oil involves several safety risks.

Before proceeding, please observe the safety information in section

WARNING - Safety risks during work with gearbox oil on page 36 .


3.

DANGER!


104



3 Maintenance

3.3.5. Inspection, oil level, gearbox axis 5

Continued

Action


5. Measure the oil level.

Required oil level to the upper edge of the oil plug hole (a): 10mm.

Note

Shown in the figure



7. Refit the oil plug. xx0500002222


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

Filling, oil, axis 5 on page 138 .



3 Maintenance




The axis 6 gearbox is located in the wrist unit as shown in the figure below. xx0200000233

A

B

C

Gearbox axis 6

Oil plug, filling

Oil plug, draining


Equipment Art. no. Note

Lubricating oil

Standard toolkit


-

3HAC032140-001 Kyodo Yushi TMO 150

Note!







Note

1.

Action

WARNING!



106



2.

Action

DANGER!


3. Open the oil plug, filling.

4. Measure the oil level.

• 55 mm ± 5 mm


3 Maintenance


Continued

Note

Shown in the figure


6. Refit the oil plug, filling.


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



3 Maintenance

3.3.7. Inspection, cable harness

3.3.7. Inspection, cable harness

Location of cable harness, axes 1-6

The robot cable harness, axes 1-6, is located as shown in the figures below.

108 xx0600002970

The figure shows the lower routing of the cable harness.

D

E

F

G

H

A

B

C

SMB/BU box

Top cover, connection box

Connection plate, base

Connector R1.SMB

Connector R1.MP

Metal clamps

Cable harness

Cable guide (cut away view)



3 Maintenance



The figure shows the upper routing of the cable harness.

D

E

F

G

A

B

C

Cable harness

Metal clamp, at gearbox axis 3

Attachment screws, metal clamp at gearbox axis 3, M6x16 quality 8.8 (2 pcs)

Metal clamp, lower arm (2 pcs)

Attachment screws, metal clamp lower arm, M6x16 quality 8.8 (2+2 pcs)

Metal clamp, armhouse

Attachment screws, metal clamp armhouse, M6x16 quality 8.8 (2 pcs)


Equipment, etc.

Standard toolkit


Circuit diagram

-

Art.no.

Note

Detailed in section



See chapter Circuit diagram .



109

3 Maintenance


Continued

Inspection cable harness, axes 1-6

The procedure below details how to inspect the cable harness of axes 1-6.

Note

1.

Action

DANGER!


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

3. Check the connectors at the base .

4. Check the cables.

Shown in the figure Location of cable harness, axes 1-6 on page 108


5. Check the metal clamps on the robot.


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

Detailed in section:

Replacement of cable harness, lower end (axes 1-2) on page 153

Replacement of cable harness, upper end on page 159


3 Maintenance

3.3.8. Inspection, information labels

3.3.8. Inspection, information labels

Location of labels

The figures below show the location of the information labels to be inspected. xx0600002980

C

E

A

B

G

Warning label "High temperature", 3HAC4431-1 (4 pcs)

Warning sign, symbol of a flash (located on motor cover), 3HAC1589-1 (5 pcs)

Warning label "Brake release", 3HAC15335-1

Instruction label "Lifting", 3HAC025472-001

Serial no. from rating label



111

3 Maintenance

3.3.8. Inspection, information labels


I

D

F

G

H

Warning label "Robot can tip forward...", 3HAC9191-1

Label Calibration, 3HAC024307-001

Serial no. from rating label

UL-label, 3HAC2763-1

AbsAcc information sign, 3HAC14257-1


Equipment

Labels and plate set

Label set, oil labels

Art. no.

3HAC025471-001

3HAC021505-003

Note

Includes all labels specified in the two previous figures! The labels are in english.

Includes only the oil labels at the gearboxes and at the robot base.

Are fitted to the robot if the gearboxes include Kyodo Yushi TMO 150.

Inspection, labels

Action

1.

Note

DANGER!


2. Check the labels, located as shown in the figures

Location of labels on page 111 .

3. Replace any missing or damaged labels. Art. no. is specified in


.


3 Maintenance

3.3.9. Inspection, mechanical stop, axis 1

3.3.9. Inspection, mechanical stop, axis 1

Location of mechanical stop

The mechanical stop axis 1 is located at the base as shown in the figure below.

xx0600002972

A

B


Fixed stop pin


Equipment, etc.

Mechanical stop ax 1

Standard toolkit

Art. no. Note

-

3HAC024014-001 To be replaced when damaged.


toolkit on page 265

.

Standard

Inspection, mechanical stop

The procedure below details how to inspect the mechanical stop axis 1.

Note

1.

Action

DANGER!


2. Inspect the mechanical stop, axis 1. Shown in the figure

Location of mechanical stop on page 113 .



113

3 Maintenance

3.3.9. Inspection, mechanical stop, axis 1

Continued

Action

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

Note


NOTE!

The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop.


3 Maintenance

3.3.10. Inspection, additional mechanical stops

3.3.10. Inspection, additional mechanical stops

Location of mechanical stops

The figure below shows the location of the additional mechanical stops on axes 1 and 3 .

Additional mechanical stops are not available for axis 2.

xx0600002938

A

B

C

D

Additional stop, axis 1

Attachment screws and washers (2 pcs)

Fixed stop




115

3 Maintenance



A

B


Attachment screw and washer


Equipment etc. Art. no. Note

Mechanical stop set, axis 1 3HAC025204-003 Includes:

• Stop +15°/-7.5°

• Stop +7.5°/-15°

• Attachment screws plus washers

• Document for movable mechanical stop

Mechanical stop set, axis 3 3HAC025290-003 Includes:

• Mechanical stop pin

• Attachment screw and washer

• Document for mechanical stop pin

Standard toolkit The content is defined in section


116



3 Maintenance


Continued

Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on axes 1and 3.

Note

1.

Action

DANGER!


2. Check the additional stops on axes 1 and 3 for damage.

Shown in the figure

Location of mechanical stops on page 115

.

3. Make sure the stops are properly attached.

Correct tightening torque, mechanical stop axis 1:

120 Nm.

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

Correct attachment screws (lubricated with Molycote

1000):

• Axis 1: M12 x 40

• Axis 3: M6 x 16



.


3 Maintenance

3.3.11. Inspection, damper axes 2-5

3.3.11. Inspection, damper axes 2-5

Location of dampers

The figure below shows the location of all the dampers to be inspected. xx0600002976

A

B

C

Damper axis 2

Damper axis 3

Damper axis 5


A damper must be replaced if damaged!

Equipment Spare part/ art. no. Note

Damper axes 2-3

Damper axis 5

Standard toolkit

3HAC12320-1

3HAC024541-001

3HAC15571-1 The content is defined in section


.

Inspection, dampers

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

Note

1.

Action

DANGER!


118



3 Maintenance

3.3.11. Inspection, damper axes 2-5

Continued

Action

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

3. Check attachment screws for deformation.

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

Note

Shown in the figure Location of dampers on page 118

.



3 Maintenance

3.3.12. Inspection, signal lamp

3.3.12. Inspection, signal lamp

Location of signal lamp

The signal lamp is located as shown in the figure below.

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, etc.

Signal lamp

Standard toolkit


-

Art. no.

3HAC10830-1

Note

To be replaced in case of detected damage.




Inspection, signal lamp

The procedure below details how to inspect the function of the signal lamp.

Action

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

Note

120



3 Maintenance

3.3.12. Inspection, signal lamp

Continued

Note Action

2.

DANGER!


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

• Checking whether the signal lamp is broken.

If so, replace it.

• Checking the cable connections.

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

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



3 Maintenance

3.4.1. Type of oil in gearboxes

3.4 Replacement / changing activities

3.4.1. Type of oil in gearboxes

Location of gearboxes

The figure show the location of the gearboxes on the robot.

xx0600002977

A

B

C

D

E

F

Gearbox, axis 1

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 4

Gearbox, axis 5

Gearbox, axis 6

122



3 Maintenance


Continued

Type of oil - historically used

The gearboxes of the robot have historically been filled with different types of oils. Today only the types of oil specified in the table is recommended.

NOTE!

When there is a change of oil types in the gearbox, it need to be rinsed. See

Rinsing gearbox on page 124

.

CAUTION!

When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified in the table!

If oils are mixed, the gearbox must be thoroughly rinsed! See Rinsing gearbox on page 124

.

Type of oil - currently used

The table show which types of oil is used in gearboxes.

Gearbox

Axis 1

Axis 2

Axis 3

Axis 4

Axis 5

Axis 6

Type of oil

Kyodo Yushi TMO 150

Kyodo Yushi TMO 150

Kyodo Yushi TMO 150

Mobilgear 600 XP320

Mobilgear 600 XP320

Kyodo Yushi TMO 150

Art. no.

Amount

3HAC032140-001 5,900 ml

3HAC032140-001 4,100 ml

3HAC032140-001 2,200 ml

11712016-604

11712016-604

5,700 ml

3,200 ml

3HAC032140-001 300 ml

Labels next to oil plugs

Labels located next to oil plugs of each gearbox show which type of oil it contains. All gearboxes must have the correct label clearly visible.

xx0800000230

Labels located next to oil plugs Currently used types of oils xx0800000241

Historically used types of oil Need to be replaced, if currently used.



123

3 Maintenance


Continued

Mixed types of oil may cause may cause severe damage!

When refilling or replacing oil in a gearbox it is important to first check which type of oil is

recommended to use in the gearbox. See Type of oil - currently used on page 123

. If the oil used is other than the one in the list of currently used types of oil, it is recommended to replace the oil.

As Kyodo Yushi TMO 150 (as well as Shell Tivela S 150) is not compatible with mineral oil, contamination with other types of oil in the gearboxes is not accepted! Equipment used in handling of Kyodo Yushi (as well as Shell Tivela S 150) must be carefully cleaned before use!

In case of changing the type of oil, the gearbox therefor must be thoroughly rinsed! See

Rinsing gearbox on page 124

.

NOTE!

When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the oil recommended by the manufacturer!

Rinsing gearbox

Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox after rinsing, use the appropiate procedure.

The same applies if the type of oil shall be changed in the gearbox.

NOTE!

What is said about Kyodo Yushi TMO 150, also applies to Shell Tivela S 150.

What is said about Mobilgear 600 XP320, also applies to Mobil Gearlube X320.

Kyodo Yushi TMO 150 mixed with Optimol Optigear RMO 150/Optigear RO 150

Use this procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150 and Optimol Optigear RMO 150/Optigear RO 150 are mixed.

• Flush the gearbox properly three times with the correct type of oil. Use a service program when flushing.

• Refill the gearbox with the correct type of oil.

Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320

Use this procedure to rinse the contaminated gearbox if the gearbox shall contain Kyodo

Yushi TMO 150 and it is mixed with Mobilgear 600 XP320.

• Flush the gearbox properly three times with Kyodo Yushi TMO 150. Use a service program when flushing.

• Refill the gearbox with Kyodo Yushi TMO 150.

124



Equipment

3 Maintenance


Continued

Equipment

Label set

Oil change equipment

Art. no.

Note

See Spare Parts.

Includes small labels to each gearbox and the complete label to be fitted at the robot base.

NOTE!

The correct labels must be fitted to the robot in case of changing of oil types!

3HAC021745-001 Includes pump with outlet pipe.


3 Maintenance

3.4.2. Oil change, gearbox axis 1

3.4.2. Oil change, gearbox axis 1

Location of oil plugs

The axis 1 gearbox is located between the frame and base. The oil plugs for filling and inspection are shown in the figure below. xx0600002958

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil

Oil collecting vessel

Oil exchange equipment

Standard toolkit

Art. no. Amount Note

-

3HAC032140-001 5,900 ml Kyodo Yushi TMO 150

Note!


-

3HAC021745-001

Capacity: 8,000 ml.


Special tools on page 266 .



.

Draining oil, axis 1

The procedure below details how to drain the oil in gearbox axis 1.

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

no. for the kit is specified in Required equipment on page 126 .

Note

1.

Action

DANGER!


126



3 Maintenance


Continued

Note

2.

Action

WARNING!


WARNING -


.

3. Collect the drained oil in an oil vessel.

Vessel capacity is specified in


4. Remove the oil plug, filling , in order to drain the oil quicker!

Shown in the figure

Location of oil plugs on page 126 .

5. Open the oil plug, draining and drain the oil into the vessel.

NOTE!

The draining is time-consuming.

Elapsed time depends on the temperature of the oil.

6. Refit the oil plug, draining .

Filling oil, axis 1

The procedure below details how to fill the oil in gearbox axis 1.

Note

1.

Action

2.

DANGER!


WARNING!


Before proceeding, please observe the safety

information in section WARNING - Safety risks during work with gearbox oil on page 36

.


Shown in the figure Location of oil plugs on page 126

.

4. Refill the gearbox with lubricating oil.

The amount of oil to be refilled depends on the amount previously being drained. The correct oil level is detailed in section

Inspection, oil level gearbox axis

1 on page 96 .

Art. no. and the total amount are

specified in Required equipment on page 126 .



127

3 Maintenance


Continued

5.

Action Note

Detailed in section

Type of oil in gearboxes on page 122

.

NOTE!

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

6. Refit the oil plug, filling . Tightening torque: 24 Nm.


3 Maintenance



Location of oil plugs

The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0600002983

The figure shows both floor and suspended mounted robot. Note that the holes are used differently depending on how the robot is mounted!

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc. Art. no.

Lubricating oil

Amount

3HAC032140-001 4,100 ml

Oil collecting vessel -


3HAC021745-001

Standard toolkit -

Note

Kyodo Yushi TMO 150

Note!


Capacity: 5,000 ml.


Special tools on page

266 .



.

Draining, oil

The procedure below details how to drain the oil in gearbox axis 2.



Note

1.

Action

DANGER!




129

3 Maintenance


Continued

2.

Action Note

WARNING!


WARNING -


.

3. Remove the oil plug, draining, and drain the gearbox oil using a hose with nipple and an oil collecting vessel.

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

Shown in the figure


Vessel capacity is specified in Required equipment on page 129 .


NOTE!

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


Filling, oil

The procedure below details how to fill oil into the gearbox, axis 2.



Note

1.

Action

2.

DANGER!


WARNING!




3. Remove the oil plug, filling and the oil plug, inspection .


The amount of oil to be refilled depends on the amount previously being drained. The correct oil level is detailed in section .

Shown in the figure


Art. no. and total amount are


130



3 Maintenance


Continued

5.

Action Note

Detailed in section

Type of oil in gearboxes on page 122 .

NOTE!


6. Refit the oil plug. Tightening torque: 24 Nm.


3 Maintenance

3.4.4. Oil change, gearbox, axis 3

3.4.4. Oil change, gearbox, axis 3


The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0600002961

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil



Standard toolkit

Art. no. Amount Note

-

-

3HAC032140-001 2,200 ml Kyodo Yushi TMO 150

Note!


3HAC021745-001 The content is defined in section


Capacity: 3,000 ml.



.

132



3 Maintenance


Continued

Draining, oil

The procedure below details how to drain oil from the gearbox, axis 3.



Action

1. Move the upper arm of the robot to the position where the wrist is pointing towards the floor.

2.

Note

This is done in order to drain all oil from the gearbox axis 3.

3.

DANGER!


WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please observe the

safety information in section WARNING -

Safety risks during work with gearbox oil on page 36 .

4. Remove the oil plug, draining, and drain the gearbox oil using a hose with nipple and an oil collecting vessel.


Shown in the figure Location of gearbox on page 132 .

Vessel capacity is specified in Required equipment on page 132

.


NOTE!

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


Filling, oil

The procedure below details how to fill oil to the gearbox, axis 3.



Note

1.

Action

DANGER!




133

3 Maintenance


Continued

2.

Action Note

WARNING!




.

3. Remove the oil plug, filling.


The amount of oil to be refilled depends on the amount previously being drained. The correct oil level is detailed in section .

Art. no. and total amount are specified in


5.

Shown in the figure


Detailed in section

Type of oil in gearboxes on page 122 .

NOTE!




3 Maintenance




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



Lubricating oil 11712016-604

Oil exchange equipment 3HAC021745-001


Standard toolkit -

-

Amount Note

5,700 ml Mobilgear 600 XP 320


section Special tools on page

266

.

Capacity: 6,000 ml.



Draining, oil xx0600002962

A

B


Oil plug, draining

The procedure below details how to drain the oil in the gearbox, axis 4.



Action

1. Run the upper arm -45° from the calibration position.

Note



135

3 Maintenance


Continued

Action

2.

Note

3.

DANGER!


WARNING!



.

4. Drain the oil from the gearbox into an vessel by opening the oil plug, draining.


Shown in the figure Location of gearbox on page 135

.



5. Run the upper arm back to its calibration position (horizontal position).

6. Refit the oil plug, draining.

Shown in section

Calibration scales and correct axis position on page 252


.

Filling, oil

The procedure below details how to fill the oil in the gearbox, axis 4.



Note

1.

Action

2.

DANGER!


WARNING!



information in section WARNING - Safety risks during work with gearbox oil on page 36 .

3. Refill the gearbox with lubricating oil through the oil plug, filling.

The amount of oil to be refilled depends on the amount previously being drained. The correct oil

level is detailed in section Inspection, oil level gearbox axis 4 on page 102

.

Shown in the figure

Location of gearbox on page 135

.

Art. no. and total amount are specified in




3 Maintenance




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


A

B


Oil plug, draining


Lubricating oil 11712016-604

Oil exchange equipment 3HAC021745-001


Standard toolkit -

-

Amount

3,200 ml

Note

Mobilgear 600 XP 320


Special tools on page 266

.

Capacity: 4,000 ml.



.

Draining, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.



Action

1. Move the robot to its calibration position.

Note

This puts the oil plug draing in the right position.

2.

DANGER!




137

3 Maintenance


Continued

3.

Action Note

WARNING!




.

4. Drain the oil from the gearbox by opening the oil plug, draining.



.



.

5. Refit the oil plug, draining. Tightening torque: 24 Nm.

Filling, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.



Action

1. Run axis 4 to a position where the oil plug, filling, is facing upwards.

2.

Note

3.

WARNING!




.

DANGER!


4. Refill the gearbox with lubricating oil through the oil plug, filling.

The amount of oil to be refilled depends on the amount previously being drained. The correct oil level is detailed in section

Inspection, oil level, gearbox axis 5 on page 104 .

Shown in the figure


.

Art. no. and total amount are




3 Maintenance




The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.

The figure shows gearbox axis 6 for IRB 6620 Foundry Plus.

xx0200000233

A

B

C

Gearbox axis 6

Oil plug, filling

Oil plug, draining



Lubricating oil IRB

6620

Lubricating oil IRB

6620 Foundry Plus


3HAC021745-001

Amount

3HAC032140-001 300 ml

450 ml

Oil collecting vessel -

Standard toolkit -

Note

Kyodo Yushi TMO 150

Note! Don´t mix with other oil types!


Special tools on page

266 .

Vessel capacity:

500 ml



.



139

3 Maintenance


Continued

Draining, oil, axis 6

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



Action

1.

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

2.

Note

Shown in the figure


3.

DANGER!


WARNING!




4. Drain the oil from the gearbox into a vessel by removing the oil plug.

5. Refit the oil plug, draining.



.


Filling, oil, axis 6

The procedure below details how to fil oil in the gearbox, axis 6.



Note

1.

Action

2.

DANGER!


140

WARNING!




3. Remove the oil plug, filling.


.



3 Maintenance


Continued

Action


The amount of oil to be refilled depends on the amount previously being drained. The correct oil

level is detailed in section Inspection, oil level gearbox axis 6 on page 106

.

5.

Note

Art. no. and the total amount are specified in


.

Detailed in section Type of oil in gearboxes on page 122 .

NOTE!




3 Maintenance

3.4.8. Replacement of SMB battery

3.4.8. Replacement of SMB battery

NOTE!

The SMB lithium battery lifetime can be extended significantly during a production break.

Activate sleep mode in IRC5 by a service routine that is described in Operating manual –

IRC5 with FlexPendant, chapter Battery shutdown service routine .

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 below.

xx0600002982

I

E

F

G

H

C

D

A

B

Attachment screws

SMB / BU unit (complete)

Velcro strap

Battery pack

SMB/BU box

Connection point, battery cable

SMB (Serial measurement board)

BU unit (Brake release unit)

Gasket (Foundry Plus)


Equipment, etc.

Battery pack

142

Standard toolkit -

Spare part no. Note

3HAC16831-1 Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved equivalent.



.



3 Maintenance


Continued

Equipment, etc.

Circuit Diagram -

Spare part no. Note


Removal, battery

The procedure below details how to remove the SMB battery.

Action

1. Move the robot to its calibration position.

Note

This is done in order to facilitate the updating of the revolution counter.

2.

3.

DANGER!


esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information in

section WARNING - The unit is sensitive to ESD! on page 35

4. Remove the SMB/BU unit by unscrewing its attachment screws.

5. Lift the SMB/BU unit out of its box and disconnect the battery cable.

Shown in the figure

Location of SMB battery on page 142

.

Shown in the figure


.

6. Remove the velcro strap that is holding the battery.

7. Remove the SMB battery.

Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved equivalent.

Shown in the figure


.

Refitting, battery

The procedure below details how to refit the SMB battery.

Note

1.

Action

DANGER!




143

3 Maintenance


Continued

2.

Action Note esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information

in section WARNING - The unit is sensitive to

ESD! on page 35

3. Reconnect the battery cable to the SMB battery pack and fit it with the velcro strap .


Shown in the figure Location of SMB battery on page 142 .

4. Put the SMB/BU unit back into the box and secure it with its attachment screws .

5. Update the revolution counter.

Shown in the figure Location of SMB battery on page 142 .

Detailed in chapter Calibration - section

Updating revolution counters on page 254 .

6.

DANGER!

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

DANGER - First test run may cause injury or damage! on page 33

.


3 Maintenance

3.5.1. Cleaning, robot

3.5 Cleaning activities

3.5.1. Cleaning, robot

General

The protection class of the robot is IP 54 except the upper arm and wrist unit which are protection class IP 67.

Activities

This instruction specifies how to clean the robot.

Periodicity

The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot. Clean a contamined robot as required.

Special points

Special points to be observed are shown in the figure below: xx0600003021

A

B

C

D

Spiral cables to motor 6

Inside of upper arm tube

Rear of upper arm tube

Inside of base/axis 1



145

3 Maintenance

3.5.1. Cleaning, robot

Continued


Equipment, etc.

Vacuum cleaner

Cloth with mild detergent

Do's and don'ts!

-

-

Art. no. Note

The section below specifies some special considerations when cleaning the robot.

Always!

• Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels!

• Always check that all protective covers are fitted to the robot before cleaning!

Never!

• Never use high pressure water cleaner or steam cleaner, when cleaning the robot!

• Never remove any covers or other protective devices before cleaning the robot!

• Never use any cleaning agents, for example compressed air or solvents, other than those specified above!

• Never spray anything on the SMB box! It has protection class IP 54!

• Never spray connectors and similar items!


4 Repair

4.1. Introduction

4 Repair


Structure of this chapter

This chapter details all repair activities recommended for the robot and any external units of the robot.

It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, for example spare parts numbers, required special tools and materials.

The procedures are gathered in sections, divided according to the component location on the robot.


All equipment required to perform a specific repair activity is listed together with the current procedure.

The equipment is also gathered in different lists in the chapter Reference information .


Before any service 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 describe danger and safety risks when performing specific steps in a procedure. Make sure to read through the chapter Safety before commencing any service work.


4 Repair

4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General

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.

Leakdown tester

Leak detection spray

Art. no.

3HAC0207-1

-

Note

Procedure

Action Note

1. Finish the refitting procedure of the motor or gear in question.

2. Remove the topmost oil plug on the gear in question, and replace it with the leakdown tester .

Adapters may be required, which are included in the leakdown tester kit.


.

3. Apply compressed air, and raise the pressure with the knob until the correct value is shown on the manometer.

4. Disconnect the compressed air supply.

Recommended value:

0.2 - 0.25 bar (20 - 25 kPa)

5. Wait for approx. 8-10 minutes. No pressure loss must be detected.

If the compressed air is significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal.

6. Was any pressure drop evident?

Localize the leak as detailed below.

Remove the leakdown tester, and refit the oil plug.

The test is complete.

7. Spray suspected leak areas with leak detection spray .

Bubbles indicate a leak.

8. 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 details how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc.

Grease

Art. no.

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Follow the instructions below when mounting a bearing on the robot.

Action

1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.

2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and other contamination. Cast components must be free from foundry sand.

3. Bearing rings, inner rings and roller elements must under no circumstances be subjected to direct impact. Furthermore, the roller elements must not be exposed to any stresses during the assembly work.

Note

Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings, when mounting a tapered bearing on the robot.

In addition to those instructions, the procedure below must be carried out to enable the roller elements to adjust to the correct position against the race flange.

Action

1. Tension the bearing gradually until the recommended pre-tension is achieved.

Note

NOTE!

The roller elements must be rotated at a specified number of turns before pre-tensioning is carried out and also rotated during the pretensioning sequence.

2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the bearing.



149

4 Repair

4.2.2. Mounting instructions for bearings

Continued

Greasing of bearings

The bearings must be greased after assembly, according to instructions below:

• 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 detailed below:

• 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 sections details how to mount different types of seals to the robot.

Equipment

Equipment, etc.

Grease

Art. no.

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below details 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.

Action Note

1. 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).

2. Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage.

3. Lubricate the seal with grease just before fitting. (Not too early as there is a risk of dirt and foreign particles adhering to the seal.)

Fill the space between the dust tongue and sealing lip to 2/

3 with grease. The rubber coated external diameter must also be greased, unless otherwise specified.


Equipment on page 151

.

4. Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in leakage.

Flange seals and static seals

The procedure below details how to fit flange seals and static seals.

Action

1. 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.



151

4 Repair

4.2.3. Mounting instructions for seals

Continued

Action

2. Clean the surfaces properly and in accordance with ABB recommendations.

3. Distribute the sealing compound evenly over the surface, preferably with a brush.

4. Tighten the screws evenly when fastening the flange joint.

O-rings

The procedure below details how to fit o-rings.

Action Note

1. Ensure that the correct o-ring size is used.

2. Check the o-ring for surface defects, burrs, shape accuracy, etc.

Defective o-rings may not be used.

3. Check the o-ring grooves.

The grooves must be geometrically correct and free from pores and contamination.

4. Lubricate the o-ring with grease.

Defective o-rings may not be used.

5. Tighten the screws evenly when assembling.


4 Repair

4.3.1. Replacement of cable harness, lower end (axes 1-2)

4.3 Complete robot

4.3.1. Replacement of cable harness, lower end (axes 1-2)

General

The cable harness 1-6 is undivided.

Replacement of the cable harness is detailed in two steps - lower end and upper end.

The procedure below details replacement of lower end of the cable harness.

The procedure for replacing the upper end is detailed in section


.

Location of cable harness, axes 1-2

The cable harness for axes 1-2 is run throughout the base and frame as shown in the figure below.

xx0600002970

A

B

C

D

SMB/BU unit

Top cover, connection box

Connection plate, base

Connector R1.SMB



153

4 Repair


Continued

E

F

G

H

Connector R1.MP

Metal clamps

Cable harness

Cable guide (cut away view)


Equipment, etc.

Cable harness

Standard toolkit

Spare part no.

Art. no.

3HAC 025054-001

-

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

Circuit diagram

Note



.


3HAC 025090-001 See chapter Circuit diagram .

Removal

The procedure below details how to remove the cable harness, axes 1-2.

Action

1. In order to facilitate refitting of the cable harness, run the robot to the specified positions:

• Axis 1: 0°

• Axis 2: 0°

• Axis 3: 0°

• Axis 4: 0°

• Axis 5: +90°

• Axis 6: no signifiance

2.

Note

DANGER!


3. Remove the top cover, connection box from the robot by removing its attachment screws.

Shown in the figure

Location of cable harness, axes 1-2 on page 153 .

154



4 Repair


Continued

Action

4. Disconnect the earth cable.

Note xx0600003028

• A: Earth (placed beneath the top cover)

• B: Top cover, connection box

5. Disconnect connectors R1.MP

and R1.SMB

on the connection plate, base .

Shown in the figure Location of cable harness, axes 1-2 on page 153 .

6. Disconnect all connectors at motors 1 R2.MP1,

R2.FB1

and 2 R2.MP2, R2.FB2

.


7. Remove the metal clamps on the frame, securing the cable harness.


8. Remove the attachment screws holding the

SMB/BU unit in its box .

The cable between the battery and the SMB/BU unit may stay connected, in order to avoid an update of the revolution counter. If the battery cable is disconnected, an updating of the revolution counter is necessary!

9. Carefully lift the SMB/BU unit out of its box , while at the same time lifting the cables of the harness.

xx0600003026

• A: Attachment screws, M5x12 quality 8.8 (7 pcs)

• B: SMB/BU unit

• C: Battery unit

• D: Box



155

4 Repair


Continued

Action

4. Disconnect the earth cable.

Note

156 xx0600003028



5. Disconnect connectors R1.MP

and R1.SMB

on the connection plate, base .


6. Disconnect all connectors at motors 1 R2.MP1,

R2.FB1

and 2 R2.MP2, R2.FB2

.


7. Remove the metal clamps on the frame, securing the cable harness.

8. Remove the attachment screws holding the

SMB/BU unit in its box .

The cable between the battery and the SMB/BU unit may stay connected, in order to avoid an update of the revolution counter. If the battery cable is disconnected, an updating of the revolution counter is necessary!


9. Carefully lift the SMB/BU unit out of its box , while at the same time lifting the cables of the harness.

xx0600003026

• A: Attachment screws, M5x12 quality 8.8 (7 pcs)

• B: SMB/BU unit

• C: Battery unit

• D: Box



Refitting

4 Repair


Continued

Action Note

10. Pull the cable harness and its connectors carefully up through the cable guide in the center of the frame.


11. Continue removal of the cable harness, axes 3-

6.

Detailed in section


159 .

The procedure below details how to refit the cable harness, axes 1-2.

Action Note

1. Push the cable harness axes 1-2 carefully down through the cable guide in the center of the frame.


2. Reconnect the connectors R1.MP

and R1.SMB

at the connection plate, base .


3. Reconnect the earth cable.

3HAC027151-001 Revision: B xx0600003028




157

4 Repair


Continued

Action

4. Put the SMB/BU unit carefully back into its box and refit its attachment screws .

Note xx0600003026

• A : Attachment screws, M5x12 quality 8.8 (7 pcs)

• B : SMB/BU unit

• C : Battery unit

• D : Box

5. Reconnect all connectors at motors 1 R2.MP1,

R2,FB1 and 2 R2.MP2, R2.FB2

.

Shown in the figure


6. Refit the metal clamps on the frame, securing the cable harness.

7. Refit the top cover, connection box .

8. Recalibrate the robot.

Shown in the figure


Shown in the figure


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

General calibration information is included in section Calibration information .

9.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are

further detailed in section DANGER - First test run may cause injury or damage! on page 33

.


4 Repair

4.3.2. Replacement of cable harness, upper end

4.3.2. Replacement of cable harness, upper end

General

The cable harness 1-6 is undivided.

Replacement of the cable harness is detailed in two steps - lower end (axes 1-2) and upper end (axes 3-6).This procedure details how to replace the cable harness that runs from axis 3 to 6.

Replacement of axes 1 to 2 is detailed in section Replacement of cable harness, lower end

(axes 1-2) on page 153

.

Location of cable harness, axes 3-6.

The cable harness for axes 3 to 6 is run throughout the lower andupper arm as shown in the figure below: xx0600003078

E

F

G

C

D

A

B

Cable harness

Metal clamp, at gearbox axis 3

Attachment screws, metal clamp at gearbox axis 3, M6x16 quality 8.8 (2 pcs)

Metal clamp, lower arm (2 pcs)

Attachment screws, metal clamp lower arm, M6x16 quality 8.8 (2+2 pcs)

Metal clamp, armhouse

Attachment screws, metal clamp armhouse, M6x16 quality 8.8 (2 pcs)


Equipment, etc.

Spare part no.

Cable harness axes 1-6 3HAC025054-001

Gasket 3HAC3537-1

Art. no.

Note


Motors axes 1-5


159

4 Repair


Continued

Equipment, etc.

Gasket

Standard toolkit

Spare part no.

3HAC12877-1

Art. no.

-


Circuit diagram

Note

Motor axis 6

The content is defined

in section Standard toolkit on page 265

.


3HAC025090-001 See chapter Circuit diagram .

Removal

The procedure below details how to remove the cable harness, axes 3-6.

Note Action

1. In order to facilitate refitting of the cable harness, run the robot to the specified positions:

• Axis 1: 0°

• Axis 2: 0°

• Axis 3: 0°

• Axis 4: 0°

• Axis 5: +90°

• Axis 6: no significance

2.

DANGER!


3. Before starting the removal of cable harness axes 3-6, first remove cable harness axes 1-2.

4. Remove the cover, wrist unit in order to reach the cable harness at axes 5 and 6.

Detailed in section

Replacement of cable harness, lower end (axes 1-2) on page

153 .

160 xx0600003024

• A : Cover, wrist unit



4 Repair


Continued

Action

5. Remove the metal clamp securing the cable harness at axis 5 by removing its attachment screws .

Note

6. Remove the cover at motor axis 5, by removing its attachment screws.

Also remove the cover motor, axis 5 by removing its attachment screws and disconnect the motor cables R2.MP5

and

R2.FB5

.

xx0600003030

• A : Cable harness

• B : Motor, axis 5

• C : Attachment screw, M6x16 8.8

(2 pcs)

• D : Metal clamp

7. Remove the cable holder in the wrist unit by undoing the three attachment screws .

Two of the attachment screws (M6x16) are visibly located at the rear of the cable holder. The third screw (M4x12) is located at the bottom of the cable holder, securing the carrier.

xx0600003032

• A : Cover

• B : Attachment screw M6X30 8.8

(2 pcs)

• C : Cover motor, axis 5

• D : Attachment screws motor

3HAC027151-001 Revision: B xx0600003034

• A : Cable holder

• B : Attachment screws M6x16, 8.8

(2 pcs)

• C : Attachment screw M4x12, 8-

A2F (securing the carrier)


161

4 Repair


Continued

Action Note

8. Remove the back cover motor, axis 6 by removing its attachment screws.

9. Pull out the cabling R2.MP6

and R2.FB6

from motor, axis 6 .

10. Disconnect all connectors at motor axis 6

R2.MP6

and R2.FB6

.

11. Remove covers motors axes 3 and 4 by removing its attachment screws.

Shown in the figure

Location of cable harness, axes 3-6. on page 159

Shown in the figure


12. Disconnect all connectors at motors axes 3

R2.MP3, R2.FB3

and 4 R2.MP4, R2.FB.4

.

Shown in the figure


13. Remove the metal clamps , two on the lower arm, one on gearbox axis 3 and one on the armhouse.

Refitting

162

14. Gently pull out the cable harness of the upper arm.

15. Tie the connectors into bundles, to avoid damaging them during further removal.

0600003083

• A : Metal clamp, lower arm (2 pcs)

• B : Metal clamp, gearbox axis 3

• C : Metal clamp, armhouse

The procedure below details how to refit the cable harness, axes 3-6.

Action Note

1. Begin by refitting the cable harness lower end, (axes 1-2).

Detailed in section Replacement of cable harness, lower end (axes 1-2) on page

153

.

2. Insert the cable harness gently from the rear into the upper arm.

Arrange the cable harness as shown in

the figure Location of cable harness, axes

3-6. on page 159

3. Place the cabling to motor axis 6, correctly on the upper arm and pull the connectors carefully through the hole on top of the wrist unit to motor, axis 6.

Shown in the figure




4 Repair


Continued

Action

4. Reconnect all connectors at motors axes 3

(R2.MP3, R2.FB3) and 4 (R2.MP4,

R2.FB4) .

5. Refit covers motor axes 3 and 4.

6. Refit the cable holder wrist unit, with the three attachment screws.

Two of the attachment screws (M6x16) are visibly located at the rear of the cable holder.

The third screw (M4x12) is located at the bottom of the cable holder, securing the carrier.

Note xx0600003034

• A : Cable holder

• B : Attachment screws M6x16, quality 8.8 (2 pcs)

• C . Attachment screws M4x12, quality 8-A2F (securing the carrier)

7. Reconnect the motor cables axis 6 R2.MP6

and R2.FB6

.

Shown in the figure


8. Refit cover motor, axis 6.

9. Reconnect the motor cables axis 5 R2.MP5

and R2.FB5

.

Shown in the figure


10. Refit the cover motor, axis 5 (C) and cover

(A) .

3HAC027151-001 Revision: B xx0600003032

• A : Cover

• B : Attachment screws M6x30, 8.8

(2 pcs)

• C : Cover motor, axis 5

• D : Attachment screws


163

4 Repair


Continued

Action

11. Refit the metal clamp securing the cable harness at axis 5.

Note

12. Refit the three metal clamps , two on the lower arm, one on gearbox axis 3 and one on the armhouse.

xx0600003030

• A : Cable harness

• B : Motor, axis 5

• C : Attachment crews M6x16, 8.8

(2 pcs)

• D : Metal clamp

164 xx0600003083

• A : Metal clamp, lower arm (2 pcs)

• B : Metal clamp, gearbox axis 3

• C : Metal clamp, armhouse



Action

13. Refit the cover, wrist unit .

4 Repair


Continued

Note xx0600003024


15.

DANGER!


DANGER - First test run may cause injury or damage! on page 33 .

xx0700000140

• A : Cover, wrist unit




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, motor and gearbox axis 1. This is shown in the figure below.

A more detailed view of the component and its position may be found in chapter .


Equipment, etc.

Lifting device, robot

Guide pins M12 x 130

166 xx0600003035

D

E

F

G

A

B

C

Upper arm

Lower arm

Motor, axis 1

Frame

Base

Gearbox, axis 1

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

Roundslings -

Art. no.

3HAC026597-001

3HAC022637-001

Note

Instruction 3HAC026600-002 is enclosed!

Used to guide the complete arm system when refitting.

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.



4 Repair


Continued

Equipment, etc.

Hoisting block

Lifting chain

Standard toolkit


-

-

-

Art. no. Note

Used to adjust the length of the lifting chain.

Used together with the hoisting block.




Removal, arm system

The procedure below details how to lift and remove the complete arm system.

Action

1. Make sure the robot is positioned as shown in figure to the right. If it is not, position it that way.

Note

Release the brakes if necessary, as detailed in section


.

xx0600003125

2.

DANGER!


3. Drain the oil from gearbox axis 1.

4. Loosen the cable connectors from the base and pull up the cabling from the base, through the hole in the center of the frame.

Detailed in section

Replacement of cable harness, lower end (axes 1-2) on page 153 .

Detailed in section Replacement of cable harness, axes 1-6 .

5. Remove the motor, axis 1.

Detailed in section Oil change, gearbox axis 1 on page 126 .

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

Detailed in section

Replacement of motor, axis 1 on page 199 .



167

4 Repair


Continued

Action Note

7. Fit the lifting device and adjust it as detailed in the enclosed instructions .

Also fit a hoisting block to the front, used to adjust the balance of the arm system in order to lift it completely level.


Make sure the lift is done completely level!

How to adjust the lift is described in the enclosed instruction to the lifting device!

Read the instructions before lifting!

NOTE!

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

xx0600003101

• A : Lifting tool

• B : Roundsling

• C : Lifting chain

• D : Hoisting block

168



4 Repair


Continued

Action Note

8.

Alternate method of lifting:

Fit the lifting device and a roundsling on the upper arm and a roundsling with a hoisting block, to the wrist unit.

Also fit a separate roundsling between the wrist and the frame in order to eliminate any load through the brake on motor axis 3.

The hoising block is used to balance the upper arm.

See the lifting instructions !



How to adjust the lift is described in the enclosed instruction to the lifting device!

Follow the instructions before lifting!

Releasing the brakes is detailed in section

Manually releasing the brakes on page 61 .

NOTE!

The brake on axis 3 shall be released during the lift, until the roundsling between the wrist and the frame transfers the load of the frame!

See figure!

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

10.

xx0600003100


• B : Roundsling



• E : Roundsling (used to transfer the load of the frame)

Shown in the figure Location of arm system on page 166 .

CAUTION!

The complete arm system weighs 590 kg!

All lifting equipment used must be sized accordingly!

11. 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 device does not wear against sharp edges.



169

4 Repair


Continued

Refitting, arm system

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

Note

1.

Action

DANGER!


2. Fit the lifting device as detailed in enclosed instruction.

Also fit a hoisting block to the front, used to adjust the balance of the arm system in order to lift it completely level!


Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting device! Follow the instructions before lifting!

NOTE!

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

170 xx0600003101


• B : Roundsling





4 Repair


Continued

Action Note

3.


Fit the lifting device and a roundsling on the upper arm and a roundsling with a hoisting block, to the wrist unit.


The hoisting block is used to balance the upper arm.

See the lifting instructions .


Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting device! Follow the instructions before lifting!


Manually releasing the brakes on page

61

.

NOTE!

The brake on axis 3 shall be released during the lift, until the roundsling between the wrist and the frame tranfers the load of the frame.

See figure to the right!

xx0600003100


• B : Roundsling




4.

CAUTION!

The complete arm system weighs 590 kg! All lifting equipment used must be sized accordingly!

5. 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.

Make sure all the hooks and attachments stay in the correct position while lifting the robot!



171

4 Repair


Continued

Action Note

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

Dimension is specified in Required equipment on page 166 .

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.

172



4 Repair


Continued

Action Note

7. 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 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!

Use a crank to turn the gearbox in order to find the right position for the holes.

NOTE!

The refitting must be made completely level!

Make sure the lifting device is adjusted prior to refitting of arm system.

xx0600003094

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

xx0600003093

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

8. 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 166 .

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 261

before fitting.

9. Refit the motor axis 1 .



173

4 Repair


Continued

Action Note

10. Refit the cabling in the base.

Detailed in section


153 .

11. Perform a leak-down test of the gearbox axis

1.

Detailed in section

Performing a leakdown test on page 148

.

12. Refill the gearbox axis 1 with lubricating oil.

Detailed in section

Oil change, gearbox axis 1 on page 126 .

13. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.


14.

DANGER!



.


4 Repair

4.4.1. Replacement of turning disk

4.4 Upper and lower arm

4.4.1. Replacement of turning disk

Location of turning disk

The turning disk is located in the front of the wrist housing, as shown in the figure below.

The figure shows turning disk on IRB 6620 Foundry Plus.


xx0600003082

A

B

C

D

E

Turning disk

Wrist unit

Oil plug, draining

Oil plug, filling

Attachment screws, turning disk (6 pcs)


Equipment, etc. Spare part no. Art. no. Note

Turning disk, diam. 200 3HAC9744-5

Turning disk, dia. 200 3HAC13752-1

O-ring

O-ring

Grease

O-rings are not included!

For IRB 6620 Foundry Plus.

O-rings are not included!

3HAB3772-65

(1 pc)

21520431-20 (6 pcs)

Must be replaced when replacing the turning disk!

3HAB3772-64

(1 pc)

3HAB3772-61

(12 pcs)

For IRB 6620 Foundry Plus.

Must be replaced when replacing the turning disk!

3HAB3537-1 Used to lubricate the o-rings.

Standard toolkit The content is defined in




175

4 Repair


Continued

Equipment, etc.


Spare part no. Art. no.

Removal, turning disk

The procedure below details how to remove the turning disk.

Note

1.

Action

Note


DANGER!


2. Remove any equipment fitted to the turning disk.

3. 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 175

.

4. Drain the oil from gearbox 6.

5. Remove the turning disk by unscrewing its attachment screws .

Detailed in section Oil change, gearbox axis 6 on page 139 .

Shown in the figure

Location of turning disk on page 175

.

176



4 Repair


Continued

Refitting, turning disk

The procedure below details how to refit the turning disk.

Action

1. Lubricate the turning disk o-ring with grease.

Fit the o-ring to the rear of the turning disk.

Also fit the six o-rings, when refitting the attachment screws.

Note



.

2. Secure the turning disk with its screws . attachment xx0200000218

• A: Sealing surface, o-ring

6 pcs M14 x 25, 12.9 quality.

Tightening torque: 175 Nm

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

section Screw joints on page 261

before fitting.

3. Perform a leak-down test of the gearbox axis 6. Detailed in section


.

4. Refill the gearbox 6 with oil. Detailed in section


5. Refit any equipment removed during disassembly, to the turning disk.

6.

DANGER!




4 Repair

4.4.2. Replacement of wrist unit

4.4.2. Replacement of wrist unit

Location of wrist unit

The wrist unit is located in the foremost part of the upper arm as shown in the figure below.

xx0600003055

I

H

D

E

F

G

A

B

C

Wrist unit

Turning disk

Cover, wrist unit

Cable holder

Cover, cable gland

Metal clamp

Wrist unit, attachment screws

Cable harness, axis 6

Cable harness, axis 5


Equipment, etc.

Wrist unit

Wrist unit, insulated

Roundsling

Grease

Standard toolkit

Spare part no.

3HAC025567-001

3HAC026168-001

Art. no.

Note

-

-

3HAB 3537-1 Used to lubricate o-rings



178



Equipment, etc.


Spare part no.

Art. no.

4 Repair


Continued

Note


Removal

The procedure below details how to remove the writ unit.

Action

1. Move the robot to a suitable position for removal of the wrist unit.

2.

Note

DANGER!


3. Remove all equipment fitted to the wrist unit .

4. Remove the cover, wrist unit in order to reach the cable harness.

5. Remove the cable harness, axes 5 and 6.

Shown in the figure in

Location of wrist unit on page 178 .

Shown in the figure Location of wrist unit on page 178 .

Detailed in section

Replacement of cable harness, upper end on page 159 .

6.

CAUTION!

The complete wrist unit weighs 96 kg! All lifting equipment used must be sized accordingly!

7. Secure the wrist unit with a roundsling in an overhead crane.

8. Unscrew the eight wrist unit.

attachment screws securing the

Shown in the figure Location of wrist unit on page 178 .

9. Remove the wrist unit from the upper arm by moving it a little back and forth until it is lose.

Note!

Don´t damage the cylindrical pin in the process!

Refitting

Action

1. Secure the wrist unit with a roundsling in an overhead crane and lift it to its mounting position.

2.

Note

CAUTION!

The complete wrist unit weighs 96 kg! All lifting equipment used must be sized accordingly!



179

4 Repair


Continued

Action

3. Put some grease on the surface of the fit.

4. Check the cylidrical pin.

5. Fit the wrist with its 8 attachment screws and washers.

6. Refit the cable harness, axes 5 and 6.

7. Refit the cover, wrist unit


.

9. Refit any equipment previously removed from the wrist unit.

10.

Note

If the pin is damaged - replace!

M12x50 12.9 gleitmo (8 pcs)

Tightening torque: 120 Nm

Detailed in section Replacement of cable harness, upper end on page 159 .

Shown in the figure

Location of wrist unit on page 178

.



DANGER!




4 Repair

4.4.3. Replacement of the upper arm

4.4.3. Replacement of the upper arm

Location of the upper arm

The upper arm is located on top of the robot as shown in the figure below.

xx0600003057

C

D

A

B

E

F

Motor, axis 3

Gearbox, axis 3

Attachment screws, M12x50 quality 12.9 Gleitmo (20 pcs)


Hole in the lower arm

Upper arm


Equipment, etc.

Spare part no.

Art. no.

Note

Upper arm (Axes 3-4) 3HAC 025576-001

O-ring

Lifting tool

Lifting chain

Roundsling

Guiding pins

Hoisting block

Grease

Standard toolkit -

-

-

-

Replace only if damaged.

3HAC 026597-001 Instruction 3HAC 026600-

002 is enclosed.

3HAB 3537-1

Always use in pairs.

Used to lubricate o-rings.


section Standard toolkit on page 265

.



181

4 Repair


Continued

Equipment, etc.


Spare part no.

Art. no.

Removal

The procedure below details how to remove the upper arm.

Note

1.

Action

Note


DANGER!



3. Raise the upper arm to a position where it is parallel to the floor, by releasing the brake of the axis 3 motor.

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 can change suddenly! Perform the procedure carefully!

Connect to connector R2.MP3:

• + : pin 2

• - : pin 5

4.

Detailed in section Oil change, gearbox, axis 3 on page 132

.

CAUTION!

The complete upper arm (incl. gearbox axis

3) weighs 282 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

182



4 Repair


Continued

Action Note

5. Fit the lifting tool on the upper arm as detailed in the enclosed instructions.

Also fit a hoisting block to the front, used to adjust the balance of the upper arm in order to lift it completely level.



.

6. Remove the cable harness, axes 3-6.

7. Remove the three metal clamps securing the cable harness on the lower arm and armhouse.

xx0600003102


• B : Roundsling



Detailed in section Replacement of cable harness, upper end on page 159

.

xx0600003083

• A: Metal clamp, lower arm (2 pcs)

• B: Metal clamp, gearbox axis 3

• C: Metal clamp, armhouse

8. Let the removed part of the cable harness hang lose, without it getting damaged when removal is proceeded.

9. Remove motor, axis 3.

10. Remove the attachment screws securing the upper arm to the gearbox axis 3.

Note! Don´t forget to remove the four screws inside the hole in the lower arm.

11. Remove the complete upper arm and put it on the floor. Let the upper arm lean on the side.

Detailed in section Replacement of motor, axis 3 on page 208

.

Shown in the figure

Location of the upper arm on page 181

.



183

4 Repair


Continued

Refitting

The procedure below details how to refit the upper arm.

Action

1. Make sure the o-ring is fitted to the gearbox.

Lightly lubricate the o-ring with grease.

2.

Note

CAUTION!

The complete upper arm (incl. gearbox axis

3) weighs 282 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

3. Fit the lifting tool on the upper arm as detailed in the enclosed instructions and lift it to its mounting position.

Also fit a hoisting block to the front, used to adjust the balance of the upper arm in order to lift it completely level.


xx0600003102


• B : Roundsling



4. Fit the guiding pins in gearbox axis 3.

5. Refit the attachment screws securing the upper arm to the gearbox.

Note ! Don´t forget the four screws inside the hole in the upper arm.

6. Remove the guiding pins.

7. Refit motor, axis 3.

Shown in the figure Location of the upper arm on page 181

.


.

184



4 Repair


Continued

Action

8. Refit the metal clamps securing the cable harness on the lower arm and armhouse.

Note

9. Refit the cable harness, axes 3-6.

10. Fill gearbox, axis 3 with oil.


12.

DANGER!


DANGER -

First test run may cause injury or damage! on page 33 .

xx0600003083

• A: Metal clamp, lower arm (2 pcs)

• B: Metal clamp, gearbox axis 3

• C: Metal clamp, armhouse

Detailed in section Replacement of cable harness, upper end on page 159

.


.




4 Repair

4.4.4. Replacement of lower arm

4.4.4. Replacement of lower arm

Location of lower arm

The location of the lower arm is shown in the figures below.

xx0600003058

A

B

C

D

E

Upper arm

Gearbox, axis 3

Lower arm

Hole in lower arm

Attachment screws, M16x50 quality 12.9 Gleitmo (16 pcs) xx0600003059

C

D

A

B

Lower arm

Hole in lower arm

Gearbox, axis 2



Equipment, etc.

Spare part no.

Art no.

Lower arm 3HAC 023618-004

Note

186



Removal

4 Repair


Continued

Equipment, etc.

Spare part no.

Art no.

Grease

Lifting tool

Lifting chain

Hoisting block

Roundslings

Guiding pins

Standard toolkit


Note

-

-

-

-

3HAB 3537-1 Used to lubricate o-rings.

3HAC 026597-001 Instruction 3HAC 026600-

002 is enclosed.

Always use in pairs.



.


The procedure below details how to remove the lower arm.

Action

1. Move the robot to the position shown in the figure to the right.

Note xx0600003125

2.

DANGER!


3. Remove the cable harness axes 3-6.

4. Let the cable harness hang lose, without it getting damaged in the proceeded removal procedure.

Detailed in section


.



187

4 Repair


Continued

Action

5. Remove the upper arm.

6. Secure the lower arm with a roundsling in an overhead crane.

7.

Note

Detailed in section Replacement of the upper arm on page 181

.

CAUTION!

The lower arm weighs 75 kg (gearboxes axes 2-3 excluded)! All lifting equipment used must be sized accordingly!

8. Remove the attachment screws and washers securing the lower arm to gearbox axis 2.

Shown in the figure

Location of lower arm on page 186

.

9. Remove the lower arm.

Refitting

The procedure below details how to refit the lower arm.

Action

1. Secure the lower arm with a roundsling and lift it to its mounting position.

2.

Note

CAUTION!

The lower arm weighs 75 kg (gearboxes axes

2-3 excluded)! All lifting equipment used must be sized accordingly!



4. Fit guiding pins in two of the holes in gearbox axis 2.

5. Lift the lower arm on to the guiding pins.

6. Refit the attachment screws and washers securing the lower arm to gearbox axis 2.

Shown in the figure

Location of lower arm on page 186 .

M16x50, quality 12.9 gleitmo (16 pcs).


7. Remove the guiding pins.

8. Secure the upper arm with a roundsling and lift it to its mounting position.

9. Refit the upper arm.

Detailed in section

Replacement of the upper arm on page 181 .

10. Refit the cable harness axes 3-6.

Detailed in section


159

.

188



Action


12.

DANGER!



4 Repair


Continued

Note




4 Repair

4.5.1. Replacement of SMB unit

4.5 Frame and base

4.5.1. Replacement of SMB unit

Location of SMB unit

The SMB/BU unit (SMB = serial measurement board, BU = brakerelease unit) is located on the left hand side of the frame as shown in the figure below.

The SMB unit and the BU unit are both located inside the SMB/BU box.

xx0600003052

I

J

E

F

G

H

C

D

A

B

Attachment screws (4 pcs)

SMB/BU unit

Velcro strap

Battery pack

SMB/BU box

Serial measurement unit (SMB), DSQC 633

Brakerelease unit (BU), DSQC 563

Push button guard

Cover, push button guard



Equipment, etc.


Serial measurement unit (SMB), DSQC

633

Standard toolkit -

Part list on page

270

Circuit diagram

Note



266 .


190



Removal, SMB unit

The procedure below details how to remove the SMB unit.

Action


2.

Note

4 Repair


Continued

3.

DANGER!


esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information in section

WARNING - The unit is sensitive to

ESD! on page 35

4. Unscrew the attachment screws of the SMB/BU unit and carefully lift it out of its box.

Shown in the figure Location of SMB unit on page 190

.

5. Carefully disconnect the connectors from the

SMB unit.

Connectors R1.SMB1-3, R1.SMB4-6 and R2.SMB

xx0600003054

6. Disconnect the battery cable from the SMB unit. Connector R1.G



191

4 Repair


Continued

Action

7. Unscrew the hexagon nuts securing the SMB unit, not more than it is possible to pull the SMB unit out.

Note

8. Pull the SMB unit out carefully.

xx0600003053

• A: Hexagon nut, M5

• B: Tooth lock washer, 6.4 fzb

• C: Hexagon screw, M5x12 quality 8.8

192



Refitting, SMB unit

The procedure below details how to refit the SMB unit.

Action

1. Push the SMB unit into its tracks and secure it with its hexagon nuts.

Note

4 Repair


Continued

2. Reconnect the connectors to the SMB unit.

xx0600003053

• A : Hexagon nut, M5

• B : Tooth lock washer, 6.4 fzb

• C : Hexagon screw, M5x12 quality 8.8

3. Reconnect the battery cable.

xx0600003054

Connector R1.G

4. Put the SMB/BU unit back into its box and refit the attachment screws.

Shown in the figure Location of SMB unit on page 190

.

5. Update the revolution counters!

Detailed in section

Updating revolution counters on page 254

.



193

4 Repair


Continued

6.

Action

DANGER!



.

Note


4 Repair

4.5.2. Replacement of brake release unit

4.5.2. Replacement of brake release unit

Location of brake release unit

The SMB/BU unit (SMB = serial measurement board, BU = brakerelease unit) is located on the left hand side of the frame as shown in the figure below.

The SMB unit and the BU unit are both located inside the SMB/BU box.

xx0600003052

I

J

E

F

G

H

C

D

A

B


SMB/BU unit

Velcro strap

Battery pack

SMB/BU box

Serial measurement unit (SMB), DSQC 633

Brakerelease unit (BU), DSQC 563

Push button guard




Equipment, etc. Art. no. Note

Brake release unit with buttons 3HAC16035-1 Located together with the SMB-unit at the left hand side of the frame.

Standard toolkit The content is defined in section


.





195

4 Repair


Continued

Removal, brake release unit

The procedure below details how to remove the brake release unit.

Note

1.

Action

2.

DANGER!


esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information

in section WARNING - The unit is sensitive to

ESD! on page 35

3. Remove the push button guard and the cover, push button guard from the SMB cover.

Shown in the figure

Location of brake release unit on page 195

.

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

4. Unscrew the attachment screws of the SMB/

BU unit and carefully lift the unit out of its box.

Let the battery stay connected, to avoid the need of synchronization of the robot!

Shown in the figure

Location of brake release unit on page 195

.

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

196

6. Remove the brake release unit from the bracket by removing the four attachment screws. xx0200000129

• A: Connector X8

• B: Connector X9

• C: Connector X10

• D: Push buttons

Location of brake release unit is shown

in the figure Location of brake release unit on page 195

.



4 Repair


Continued

Refitting, brake release unit

The procedure below details how to refit the brake release unit.

Note

1.

Action

2.

DANGER!


esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information in section

WARNING - The unit is sensitive to

ESD! on page 35

3. Fasten the brake release unit on the bracket with the attachment screws.

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

Shown in the figure

Location of brake release unit on page 195 .


.

4. Connect the connectors X8, X9 and X10 to the brake release unit. xx0200000129

• A: Connector X8

• B: Connector X9

• C: Connector X10

• D: Push buttons

5. Put the SMB/BU unit carefully back into its box and refit its attachment screws.

The push button guard must not be mounted on the cover before the check described below is made!

Shown in the figure




197

4 Repair


Continued

Action

6.

Note

WARNING!

Before continuing any service work, please observe the safety information in section

WARNING - The brake release buttons may be jammed after service work on page 34

!

7. Refit the push button guard and the cover, push button guard to the SMB cover.

Shown in the figure


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

Detailed in the Calibration chapter -

section Updating revolution counters on page 254

.

9.

DANGER!




4 Repair

4.6.1. Replacement of motor, axis 1

4.6 Motors

4.6.1. Replacement of motor, axis 1

Location of motor

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

xx0600003037

C

D

A

B

Motor, axis 1

Motor attachment screws and washers

Cable gland

Cover


Equipment, etc. Spare part no.

Motor including pinion 3HAC15879-2

3HAC024518-003

O-ring

Grease

Removal tool, motor

M12x

Lifting tool, motor ax 1,

4, 5

Art. no.

21522012-430

3HAB3537-1

3HAC14973-1

3HAC14459-1

Note

Includes

• motor

• pinion

• o-ring 21522012-

430.

Must be replaced when reassembling motor!

Used to lubricate the oring.

Always use the removal tools in pairs!



199

4 Repair


Continued

Equipment, etc. Spare part no.

Power supply -

Art. no.

Standard toolkit -

Calibration Pendulum toolkit


Circuit Diagram -

3HAC15716-1

Note

24 VDC, max. 1,5 A

For releasing the brakes.



.

Complete kit that also includes operating manual.



Removal, motor axis 1

The procedure below details how to remove motor, axis 1.

Note

1.

Action

DANGER!


2. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws.

Shown in the figure Location of motor on page 199

.

3. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

200

NOTE!

Make sure the gasket is not damaged!

4. Disconnect all connectors beneath the motor cover. xx0200000199

• A: Cable gland cover

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


6. In order to release the brakes, connect the 24 VDC power supply.

Connect to connector R2.MP1

• +: pin 2

• -: pin 5

7. Remove the motor by unscrewing its four attachment screws and plain washers.


.



4 Repair


Continued

Action Note

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



9.

CAUTION!

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

10. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

11. Remove the motor by gently lifting it straight up.

Refitting, motor axis 1

The procedure below details how to refit motor, axis 1.

Action

1.

Note

DANGER!


2. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.

Art no. is specified in


.

3.

CAUTION!


4. Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in


.

5. In order to release the brake, connect the 24 VDC power supply.

6. Fit the motor, making sure the motor pinion is properly mated to gearbox of axis 1.

7. Secure the motor with its four attachment screws and plain washers.

8. Disconnect the brake release voltage.


• +: pin 2

• -: pin 5

Make sure the motor is turned the correct way, that is connection of

motorcable as shown in the figure -

Location of motor on page 199

.

Make sure the motor pinion does not get damaged!

M10 x 40, tightening torque: 50

Nm.

9. Reconnect all connectors beneath the motor cover.

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

Make sure the cover is tightly sealed!



201

4 Repair


Continued

Action

11. Refit the motor cover with its four attachment screws.

12. Recalibrate the robot!

Note




13.

DANGER!



.


4 Repair

4.6.2. Replacement of motor axis 2

4.6.2. Replacement of motor axis 2


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

xx0600003940

A

B

C

Motor, axis 2

Motor attachment holes (4 pcs)

Cable gland


Equipment, etc.

Motor including pinion

O-ring

Grease

Removal tool, motor

M12x

Guide pins M10 x

150

Lifting tool, motor ax

2,3

Extension bar, 300 mm for bits 1/2"

Power supply


Spare part no.

3HAC024512-003

Art. no.

21522012-430

3HAB3537-1

3HAC14973-1

3HAC15521-2

Note

Includes

• motor

• pinion

• o-ring 2152 2012-

430


For lubricating the o-ring.


For guiding the motor.

Guides are to be used in pairs!

3HAC026061-001

3HAC12342-1

24 VDC, 1.5 A



203

4 Repair


Continued

Equipment, etc. Spare part no. Art. no.

Rotation tool 3HAC17105-1

Standard toolkit

Calibration

Pendulum toolkit


Circuit diagram

-

3HAC15716-1

Note

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






Removal, motor

204

The procedure below details how to remove the motor, axis 2.

Action Note

1. Secure the robot from collapsing once the motor axis 2 is removed, by following the procedure detailed below:

• Move the lower arm as far back as possible.

• Release the brakes on motor axis 2 which will enable the lower arm to rest on its mechanical stop .

• The motor axis 2 can now be replaced without securing the robot in an overhead crane.

Releasing brakes are detailed in

section Manually releasing the brakes on page 61

.

2.

DANGER!


3. Drain the oil from gearbox, axis 2. Detailed in section


.

4. Remove the cover on top of the motor by unscrewing its four attachment screws.


Shown in the figure

Location of motor on page 203 .


6. Disconnect all connectors beneath the motor cover.



4 Repair


Continued

7.

Action Note

Use the lock screw to lock the lower arm, as detailed above!

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!



• +: pin 2

• -: pin 5


10. Fit the two guide pins attachment holes.

in two of the motor

12. Remove the removal tools and fit the

13.

motor axis 2, 3, 4 to the motor. lifting tool,



.

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



.



CAUTION!


14. Lift the motor to get the pinion away from the gear. Make sure the motor pinion does not get damaged!

15. Remove the motor by gently lifting it straight out and place it on a secure surface. Disconnect the brake release voltage.

Refitting, motor

The procedure below details how to refit the motor axis 2.

Note

1.

Action

DANGER!






205

4 Repair


Continued

Action Note

3. In order to release the brake, remove the cover on top of the motor and connect the 24

VDC power supply.


• +: pin 2

• -: pin5

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

5. Fit the two guide pins in the two lower motor attachment holes.




.

6.



CAUTION!


7. Lift the motor and guide it on to the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

Make sure that the motor is turned the right direction, that is the cables facing as shown in

the figure Location of motor on page 203

.

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

9. Use the rotation tool in order to rotate the motor pinion when mating it to the gear (see the figure to the right). Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox axis 2 and that it doesn´t get damaged.



206

10. Remove the guide pins. xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

• A: Rotation tool

11. Secure the motor with four attachment screws and plain washers.

M10 x 40, tightening torque: 50 Nm.


Screw joints on page 261 before fitting.



Connect in accordance with markings on connectors.



.



4 Repair


Continued

Action Note

15. Refit the cover on top of the motor with its four attachment screws.


16. Perform a leak down test.

17. Refill the gearbox with oil.

Detailed in

Performing a leak-down test on page 148

.

Detailed in section Oil change, gearbox axis 2 on page 129

.

18. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.


19.

DANGER!


further detailed in section DANGER - First test run may cause injury or damage! on page 33 .


4 Repair




The motor axis 3 is located on the left hand side of the robot as shown in the figure below. xx0600003051

A

B

C

Cable gland cover, motor axis 3


Motor, axis 3



Motor, axis 3 3HAC024771-003

208

O-ring

Grease

Guide pins M10 x

100

Guide pins M10 x

150

Rotation tool

Power supply

Standard toolkit

-

-

21522012-430

3HAB3537-1

3HAC15521-1

3HAC15521-2

3HAC17105-1

Note

Includes:

• motor

• pinion

• o-ring 21522012-430





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

24 VDC, max. 1.5 A



section Standard toolkit on page 265

.



4 Repair


Continued


Calibration

Pendulum toolkit


Circuit Diagram

3HAC15716-1

Note




Removal, motor


Action

1. Move the robot to the position shown in the figure.

This is done in order to drain all oil from the gearbox axis 3.

Note


3.

xx06000030414


.

DANGER!


4. Secure the robot from collapsing once the motor axis 3 is removed, by following the procedure detailed below:

• Move the lower arm as far back as possible.

• Release the brakes on motor axis 2 and let the lower arm rest on its mechanical stop.

• Also release the brakes on motor axis 3 and let the upper arm rest on its mechanical stop.

• The lower and upper arms now rests on their respective mechanical stops. The motor axis

3 can now be replaced without securing the armsystem in an overhead crane.

Detailed in section Manually releasing the brakes on page 61 .

5. Remove any equipment hindering access to motor axis 3.



209

4 Repair


Continued

Action Note


7. Remove the cable gland cover at the cable exit by unscrewing its two securing screws.


9.


.


DANGER!

Secure the weight of the upper arm properly before releasing the brakes of motor, axis 3.

When releasing the holding brakes of the motor, the upper arm will be movable and may fall down!

10. Release the brake by connecting the 24 VDC power supply.


• +: pin 2

• -: pin 5

11. Unscrew the motors four attachment screws and plain washers .


.

12. Fit the two guide pins in two of the motor attachment screw holes.



13. Press the motor out of position by fitting removal tool, motor to the remaining motor attachment screw holes.




14. Apply the lifting tool, motor axis 2 ,3, 4 to the motor. Art. no. is specified in


15.

CAUTION!


16. Lift the motor to get the pinion away from the gear.

17. Remove the motor by gently lifting it straight out and disconnect the brake release voltage.

Make sure the motor pinion is not damaged!



Action

1.

Note

DANGER!


210



4 Repair


Continued

Action Note

2. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate it with grease .

Art no. is specified in Required equipment on page 208 .

3. Fit the lifting tool, motor axis 2, 3, 4

to the motor. Art no. is specified in Required equipment on page 208 .

4. Fit the two guide pins in the two lower motor attachment holes.



5.

CAUTION!


6. Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

7. Remove the lifting tool and allow the motor stay on the guide pins.



• +: pin 2

• -: pin 5

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

Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 3.



Make sure the motor is turned the right direction, that is the cables facing forwards.

10. Remove the guide pins.




3HAC027151-001 Revision: B xx0200000165


• A: Rotation tool.

4 pcs: M10 x 40, tightening torque:

50 Nm.

Connect in accordance with markings on connectors.


211

4 Repair


Continued

Action Note



Shown in the figure



16. Remove the equipment used to unload the upper arm.

17. Perform a leak-down test.



Detailed in section

Performing a leak-down test on page 148

.

Detailed in section

Oil change, gearbox, axis 3 on page 132 .

19. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.


20.

DANGER!



.


4 Repair




The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. xx0500003050

A

B

C

Cable gland cover, motor axis 4

Motor, axis 4



Equipment, etc.

Spare part no.

Art. no.

Motor, axis 4 3HAC024782-003

O-ring

Grease

Guide pins M8 x 100

Guide pins M8 x 150

Rotation tool

Power supply

Standard toolkit

Calibration

Pendulum toolkit

-

-

21522012-430

3HAC3537-1

3HAC15520-1

3HAC15520-2

3HAC17105-1

3HAC15716-1

Note

Includes:

• motor

• pinion

• o-ring 21522012-430


Used to lubricate the o-ring.



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

24 VDC, max. 1,5 A




.




213

4 Repair


Continued

Equipment, etc.

Spare part no.

Art. no.


Circuit Diagram

Note



Removal, motor axis 4


Action Note

1. Move the robot to a position where the upper arm is pointed straight up.

This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

Any other position of the upper arm requires a draining of oil from the gearbox for axis 4.

Draining of oil is described in section

Draining, oil on page 135 .

2.

214

DANGER!


3. Remove the cable gland cover at the cable exit of the motor by unscrewing its two attachment screws.


.




6. In order to release the brake, connect the 24

VDC power supply.


• +: pin 2

• -: pin 5

7. Unscrew the motors four attachment screws and plain washers.


.







11. Remove the motor by gently lifting it straight out.




Refitting, motor axis 4


Note

1.

Action

4 Repair


Continued

DANGER!



3. Fit the lifting tool to the motor.


4. In order to release the brakes, connect the

24 VDC power supply.

5. Fit the two guide pins attachment holes.

in two of the motor


Connect to connector R2.MP4:

• +: pin 2

• -: pin 5



.

6. Fit the motor, with guidance of the pins, making sure the motor pinion is properly mated to the gear of gearbox 4.


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

Fit the motor, making sure the motor pinion is properly mated to the gear, axis 4.



Make sure the motor is turned the right direction, that is the cables facing forwards.




11. Reconnect all connectors beneath the motor cover. xx0200000165


• A: Rotation tool.

4 pcs: M8 x 25, tightening torque: 24 Nm.



215

4 Repair


Continued

Action Note





.

14. Perform a leak-down test if gearbox has been drained.

Detailed in section


.

15. Refill the gearbox with oil if drained.

16. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.


17.

DANGER!



.


4 Repair




The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below.


xx0600003049

C

D

A

B

E

Cable harness

Motor, axis 5


Metal clamp

Cover, cable gland


Equipment, etc.

Motor, axis 5

O-ring

Grease

Removal tool, motor

M10x

Extension bar 300 mm for bits 1/2"

Guide pins M8 x 100

Guide pins M8 x 150

Power supply

Standard toolkit


Spare part no.

3HAC024782-003

Art. no.

21522012-430

3HAC3537-1

3HAC14972-1

3HAC12342-1

3HAC15520-1

3HAC15520-2

-

-

Note

Includes:

• motor

• pinion

• o-ring






24 VDC, 1.5 A




.


217

4 Repair


Continued



Circuit Diagram

Note



Removal, motor, axis 5


Action

1. Move the robot to a position where the upper arm is parallel to the floor and the side of the wrist unit, where motor axis 5 is placed, is facing up.

2.

Note

218

DANGER!


3. Remove the cover on the wrist unit by removing its attachment screws.

4. Remove the metal clamp securing the cable harness.

Shown in the figure in section






7. Disconnect all connectors beneath the motor cover and remove the cable of the axis 5 motor.

8. Pull the cable harness out of the upper arm a little, far enough in order to make room for removal of the motor.




Connect to:

- connector R2.MP5 (in the motor):

• + : pin 2

• - : pin 5



12. If required, press the motor out of position by fitting removal tool, motor, M10 to the motor attachment screw holes.



Always use the removal tools in pairs and diagonally!





4 Repair


Continued

Action Note

14. Remove the motor by gently lifting it straight out. Keep track of the shims between the motor flange and the wrist housing.

Refitting, motor, axis 5


Note

1.

Action

DANGER!




VDC power supply.

4. Fit the two guide pins in two of the motor attachment holes.


Connect to:

- connector R2.MP5 (in the motor):

• + : pin 2

• - : pin 5


5. Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of axis 5.



4 pcs: M8 x 25; tightening torque: 24

Nm.


8. Refit the cable of the axis 5 motor and reconnect all connectors beneath the motor cover.




11. Refit the metal clamp securing the cable harness.

12. Perform a leak-down test.

Shown in the figure in section of motor on page 217

Detailed in section

.

down test on page 148

.

Location

Performing a leak-

13. Refit the cover of the wrist unit with its attachment screws.

14. Refill the gear with oil.


Detailed in section


.





219

4 Repair


Continued

Action

16.

DANGER!



.

Note


4 Repair

4.6.6. Replacement of motor, axis 6, IRB 6620/Foundry Plus

4.6.6. Replacement of motor, axis 6, IRB 6620/Foundry Plus


The motor axis 6 is located in the center of the wrist unit as shown in the figure below.


xx0600003039

A

B

Wrist unit

Motor, axis 6


Equipment, etc.



(Foundry Plus)


(insulated)

O-ring

Gasket

Removal tool, motor

M10x


3HAC15990-4

3HAC14211-1

3HAC14990-4

3HAC12877-1

Note

Includes:

• motor

• pinion

• o-ring 21522012-430

Includes:

• motor

• pinion

• o-ring 21522012-430

21522012-430 Must be replaced when reassembling motor!

Must be replaced when replacing motor

3HAC14972-1 Always use the removal tools in pairs!



221

4 Repair


Continued

Equipment, etc.

Extension bar 300 mm for bits 1/2"

Guide pins M8 x 100

Guide pins M8 x 150

Power supply

Grease

Standard toolkit

Calibration Pendulum toolkit


Circuit Diagram


3HAC12342-1

-

Note

-

3HAC15520-1 For guiding the motor.

3HAC15520-2 For guiding the motor.

24 VDC, 1.5 A


3HAB3537-1 For lubricating the o-ring.

- The content is defined in


3HAC15716-1 Complete kit that also includes operating manual.



Removal, motor


Action

1. Move the robot to a position where the motor in axis

6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

2.

Note

DANGER!


3. Remove the rear motor cover by unscrewing the five attachment screws.

4. Disconnect all connectors beneath the cover.



• +: pin 2

• -: pin 5

222



4 Repair


Continued

Action


Note xx0600003038

• A: Tilthouse

• B: Motor, axis 6

• C: Attachment screws (4 pcs)




8. Lift the motor carefully to get the pinion away from the gear and disconnect the brake release voltage.


9. Remove the motor by gently lifting it straight out.



Action Note

1. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the oring with grease.



VDC power supply.


• +: pin 2

• -: pin 5

3. Fit the two guide pins in two of the motor attachment holes.




223

4 Repair


Continued

Action Note

4. Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of gearbox, axis 6.

Make sure the pinion on the motor shaft is not damaged!

224


6. Secure the motor with its four attachment screws and plain washers.

4 pcs: M8 x 25, tightening torque: 24

Nm.

7. Disconnect the brake release voltage. xx0600003038

• A: Tilthouse

• B: Motor, axis 6

• C: Attachment screws


9. Refit the cover on top of the motor with its five attachment screws.





11.

DANGER!




4.7 Gearboxes

4.7.1. Replacement gearbox axis 1

Location of gearbox axis 1

4 Repair

4.7.1. Replacement gearbox axis 1 xx0600003068

D

E

F

A

B

C

Gearbox, axis 1 RV 320C-191.35

Attachment screw, M12x80 quality 12.9 gleitmo (16 pcs)


Base

Frame

Cable guide


Equipment, etc.

Spare part no.

Gearbox, axis 1

O-ring

Support, base and gear axis 1

Guide pins

Art. no.

Note


• gearbox

• o-ring

3HAB3772-93

3HAC15535-1

Replace only when damaged.

Consists of 4 pcs.

Always use guiding pins in pairs.



225

4 Repair

4.7.1. Replacement gearbox axis 1

Continued

Equipment, etc.

Spare part no.

Lifting tool

Lifting tool

Lifting eye (2 pcs)

Grease

Standard tools


Art. no.

Note

3HAC026597-001 Instruction 3HAC026600-

002 is enclosed.

3HAC15556-1 Used to lift gearbox axis 1 and frame.

3HAC025333-005 Used together with lifting tool 3HAC15556-1.

-

3HAB3537-1 For lubricating o-rings.




Removal

The procedure below details how to remove the gearbox axis 1.

Action


Note

226 xx0600003125

2.

DANGER!



4. Remove motor, axis 1.

Detailed in section


Detailed in section

Replacement of motor, axis 1 on page 199 .



4 Repair


Continued

Action Note


Secure the cable harness to the robot in a safe way, that it will not be damaged in the continued removal procedure.

Detailed in section


153 .

6. Run an overhead crane to a position above the robot.

7.

CAUTION!



8. Fit the lifting tool and adjust as detailed in the enclosed instructions.

Also fit a hoisting block to the front, used to adjust the balance of the armsystem in order to lift it completely level.



How to adjust the lift is described in the enclosed instruction to the lifting tool.


NOTE!

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

3HAC027151-001 Revision: B xx0600003101


• B : Roundsling




227

4 Repair


Continued

Action Note

9.


Fit the lifting tool and a roundsling on the upper arm and a roundsling with a hoisting block, to the wrist unit.








Manually releasing the brakes on page

61

.

NOTE!


10. Remove the attachment screws and serrated lock washers securing the gearbox axis 1 to the frame.

xx0600003100


• B : Roundsling




228 xx0600003070

• A: Serrated lock washer

• B: Gearbox, axis 1

• C: Attachment screw, M12x80

11. Lift the robot (without the base) and put it safely on its side on the floor.

12. Remove the robot´s attachments screws in order to unfasten the base from the foundation.

Detailed in section

Orienting and securing the robot on page 68

.



4 Repair


Continued

Action

13. Fit two lifting eyes on each side of the gearbox and secure it with a roundsling.

14. Attach the lifting tool to the gearbox.

15.

Note



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!

16. Lift the robot base with gearbox axis 1, to allow fitting the support, base and gear axis

1 on each side of the base.


17. Fit the support, base and gear axis 1.

Make sure the base remains in a stable position before performing any work underneath the base!

18. Unscrew the 12 attachment screws and washers securing the gearbox to the base.

xx0600003069

• A: Gearbox, axis 1

• B: Attachment screw, M16x60

19.

CAUTION!

The gearbox weighs 108 kg! All lifting equipment used must be sized accordingly!

20. Remove the gearbox.

Refitting

The procedure below details how to remove the gearbox axis 1.

Action Note

1. If the base not already is resting on the support base and gear, axis 1 , this should be done first.

Mounting of the support base and gear, axis 1 is detailed in section

Removal on page 226 .



229

4 Repair


Continued

Action Note

2. Make sure the o-ring is fitted to the gearbox as shown in the figure to the right.




.

230

3. Refit the cable guide in the center of gearbox 1 with its attachment screws.

4. Fit two lifting eyes on each side of the gearbox and secure it with a roundsling.

5. Fit two guide pins in two of the attachment holes, parallel to each other.

6.

xx0200000055

• A : O-ring (Gearbox shown from the side)

Shown in the figure

Location of gearbox axis 1 on page 225

.



.

CAUTION!


7. Lift the gearbox on to the guide pins and lower it carefully to its mounting position.



Action

8. Refit the gearbox to the base with its attachment screws and washers.

4 Repair


Continued

Note

Shown in the figure Location of gearbox axis 1 on page 225 .

M16x60 quality 12.9 (12 pcs)


xx0600003069

• A: Gearbox, axis 1

• B: Attachment screw, M16x60

9.

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!

10. Lift the robot base and gearbox 1 to allow removing the support, base and gear.

11. Secure the base to the mounting site.

Detailed in section

Orienting and securing the robot on page 68

.

12.

CAUTION!





231

4 Repair


Continued

Action Note

13. Fit the lifting tool and adjust as detailed in the enclosed instructions.

Also fit a hoisting block to the front, used to adjust the balance of the armsystem in order to lift it completely level.



.




NOTE!

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

xx0600003101


• B : Roundsling

• C : Lifting sling


232



4 Repair


Continued

Action Note

14.


Fit the lifting tool and a roundsling on the upper arm and a roundsling with a hoisting block, to the wrist unit.





.




Releasing the brakes is detailed in

section Manually releasing the brakes on page 61 .

NOTE!


15. Refit the robot to the base with its attachment screws and serrated lock washers.

NOTE!

The orientation of the serrated lock washer must be fitted as is shown in the figure to the right!

xx0600003100


• B : Roundsling




Shown in the figure Location of gearbox axis 1 on page 225 .

M12x80 quality 12.9 (16 pcs)



3HAC027151-001 Revision: B xx0600003069

• A: Serrated lock washer

• B: Gearbox, axis 1

• C: Attachment screw, M12x80

Detailed in section Replacement of cable harness, lower end (axes 1-2) on page

153

.


233

4 Repair


Continued

Action

17. Refit motor, axis 1.

18. Fill oil in gearbox axis 1.


20.

DANGER!


further detailed in section DANGER - First test run may cause injury or damage! on page 33 .

Note


.


.




4 Repair


4.7.2. Replacement gearbox axis 2


The gearbox axis 2 is located in the lower arm rotational center.


A

B

C

D



Motor, axis 2

Gearbox, axis 2

Equipment, etc

Gearbox, axis 2

O-ring

Grease

Lifting tool

Lifting tool

Roundsling

Guide pins

Crank

Standard toolkit

Spare part no.

Art. no.

Note


• gearbox

• o-ring

3HAB3772-91

Option Foundry Prime

3HAC026621-001 Option Foundry Prime

Equivalent:

• Mercasol 3106

3HAB3537-1 For lubricating o-rings.

3HAC026597-001 Instruction 3HAC026600-002 is enclosed.

3HAC025214-001 For lifting gearbox

-

-

Always use in pair.

3HAC020999-001 Used to turn the gear in correct position.





235

4 Repair


Continued

Equipment, etc


Spare part no.

Art. no.

Removal

The procedure below details how to remove gearbox axis 2.

Action

1. Move the robot to the position, shown in the figure to the right.

Note

Note


236 xx0600003125

2.

DANGER!



4.

CAUTION!

The upper and lower arms (incl. gearboxes axes 2 and 3) weighs 455 kg. All lifting equipment used must be sized accordingly!

Detailed in section


.



4 Repair


Continued

Action Note

5. Fit the lifting tool on the upper arm and secure the robot in an overhead crane.




xx0600003102


• B : Roundsling



Detailed in section

Replacement of cable harness, lower end (axes 1-2) on page 153 .

7. Let the removed part of the cable harness hang lose, without it getting damaged when removal is proceeded.

8. Remove the attachment screws M16x50 (16 pcs) securing the lower arm to gearbox axis 2.

Shown in the figure Location of gearbox axis 2 on page 235

.

9. Remove the upper and lower arms and let them hang lifted while removing the gearbox from the frame.

10. Remove the attachment screws M12x60 (24 pcs) securing the gearbox to the frame.

11. Remove motor axis 2.


.

Detailed in section

Replacement of motor axis 2 on page 203

.

12. Fit two guide pins in two of the holes, parallel to each other.

13.

CAUTION!


14. Fit the lifting tool for lifting the gearbox, in the uppermost hole and secure it with a roundsling.



15. Remove the gearbox and put it in a place where it is not damaged.

16. Wipe clean from residual oil and paint.



237

4 Repair


Continued

Refitting

The procedure below details how to refit gearbox axis 2.

Action


Lightly lubricate it with grease.

Note xx0600003128

• A : O-ring 3HAB3772-91

2.

CAUTION!


3. Fit the lifting tool for lifting the gearbox in the uppermost hole of the gearbox and secure it with a roundsling.



.


5. Lift the gearbox on to the guide pins and push it in mounting position.

6. Refit the gearbox with its attachment screws.

M12x60 (24 pcs)


7.

CAUTION!

The upper and lower arms (incl. gearboxes axes 2 and 3) weighs 455 kg. All lifting equipment used must be sized accordingly!

238



4 Repair


Continued

Action Note

8. Fit the lifting tool on the upper arm and secure the robot in an overhead crane and lift it carefully up to its mounting position.



9. Use a crank in the gearbox in order to find the holes for the attachment screws.

10. Refit the lower arm to the gearbox axis 2 with its attachment screws.

M16x50 (16 pcs)


11. Refit motor axis 2.

Detailed in section

Replacement of motor axis 2 on page 203

.


13. Fill the gearbox axis 2 with oil.


xx0600003099


• B : Roundsling



Detailed in section

Replacement of cable harness, lower end (axes 1-2) on page 153

.

Detailed in section


.



15.

DANGER!




4 Repair

4.7.3. Replacement of gearbox axis 3

4.7.3. Replacement of gearbox axis 3


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

xx0600003057

A

B

C

D

E

Motor, axis 3

Gearbox, axis 3



Hole in lower arm


Equipment, etc.

Gearbox, axis 3

O-ring

Grease

Lifting tool

Lifting tool

Standard toolkit

Spare part no.

Art. no.

Note

3HAC 025007-001 Includes:

• gearbox

• o-ring

3HAB 3772-92 Replace only if damaged.

-

3HAB3537-1 Used to lubricate the o-ring.

3HAC 026597-001 Instructions 3HAC 026600-002 is enclosed.

3HAC 025214-001 For lifting gearbox.



266

.

240



Removal

Equipment, etc.


Spare part no.

Art. no.

4 Repair


Continued

Note


The procedure below details how to remove gearbox axis 3.

Note Action


xx0600003125

2.

DANGER!



4. Remove the upper arm.

Detailed in section


.

Detailed in section

Replacement of the upper arm on page 181 .

5. While the upper arm is resting on its side on the floor, fit the lifting tool in the uppermost hole of the gearbox.


6.

CAUTION!


7. Secure the gearbox with a roundsling in an overhead crane.



241

4 Repair


Continued

Action Note

8. Remove the attachment screws securing the gearbox to the upper arm.

9. Remove the gearbox and put it in a safe place.


.

Refitting

The procedure below details how to refit gearbox axis 3.

Note Action



242 xx0600003127

• A : O-ring 3HAB 3772-92

2.

CAUTION!


3. Fit a lifting tool in the uppermost hole of the gearbox and secure it with a roundsling.



5. Lift the gearbox on to the guide pins and push it to its mounting position.

6. Refit the gearbox, while the upper arm is resting on its side on the floor.

7. Refit the upper arm .

Detailed in section Replacement of the upper arm on page 181 .

8. Fill the gearbox axis 3 with oil.



.





10.

Action

DANGER!

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

detailed in section DANGER - First test run may cause injury or damage! on page 33

.

4 Repair


Continued

Note


4 Repair

4.7.4. Replacement of gearbox, axis 6

4.7.4. Replacement of gearbox, axis 6


The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0200000219

A

B

C

D

-

Gearbox, axis 6

Attachment screws and washers, gearbox (18 pcs)

Oil plug, draining

Oil plug, filling

O-ring (not shown in figure)

244 xx0600003085

C

D

A

B

Gearbox, axis 6 (IRB 6620)

Attachment screws, gearbox

Oil plug, draining

Oil plug, filling



E

F

Turning disk

Attachment screws, turning disk

4 Repair



A

B

C

D

Gearbox, axis 6 (IRB 6620 Foundry Plus)

Attachment screws and washers

Oil plug, draining

Oil plug, filling



Gearbox 3HAC10828-10

Gearbox

O-ring

Grease

Standard toolkit

Calibration

Pendulum toolkit


3HAC10828-13

Note

Includes o-ring 3HAB3772-

58.

(IRB 6620 Foundry Plus)

Includes o-ring 3HAB3772-

57.

Must be replaced when reassembling gearbox!

3HAB3772-58

3HAB3772-64

3HAB3772-61

3HAB3537-1

-

3HAC15716-1




.





245

4 Repair


Continued

Removal, gearbox

The procedure below details how to remove gearbox, axis 6.

Action

1.

Note

DANGER!


2. Drain the oil from gearbox, axis 6.

3. Remove the turning disk .

Detailed in section


.

Detailed in section Removal, turning disk on page 176

.

4. Remove the gearbox by unscrewing its 8 attachment screws.

5. If required, apply M8 screws to the holes shown in the figure beside to press the gearbox out.

Shown in the figure


.

6. Remove the gearbox axis 6 by lifting it out carefully. xx0200000220

• A: M8 holes for pressing out the gearbox

Be careful not to damage the motor pinion!

Refitting, gearbox

The procedure below details how to refit gearbox, axis 6.

Note

1.

Action

DANGER!


246



4 Repair


Continued

Action Note

2. Make sure the o-ring is fitted to the rear of the gearbox. Lubricate the o-ring with grease.



. xx0100000132

• A: O-ring, gearbox axis 6

3. Release the holding brake of motor axis 6. Detailed in section Manually releasing the brakes on page 61 .

4. Insert the gearbox, axis 6 into the wrist unit. Art. no. is specified in


.

Shown in the figure


Make sure the gears of the gearbox mate with the gears of the motor!

5. Secure the gearbox with the attachment screws and washers.

Shown in the figure


8 pcs : M8 x 40, 12.9 quality UNBRAKO,



Screw joints on page 261

before fitting.

6. Refit the turning disk .

7. Perform a leak-down test .

Detailed in section Refitting, turning disk on page 177 .

Detailed in section

Performing a leak-down test on page 148 .




.





247

4 Repair


Continued

Action

10.

DANGER!

Make sure all safety requirements are met when performing the first test run. These

are further detailed in section DANGER -

First test run may cause injury or damage! on page 33

.

Note


5 Calibration information

5.1. Introduction



General

This chapter includes general information about different calibration methods and also details procedures that do not require specific calibration equipment.

When the robot system must be recalibrated, it is done according to documentation enclosed with the calibration tools.

When to calibrate

The system must be calibrated if any of the below occurs.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different

methods are briefly described in section Calibration methods on page 250 , and further

detailed in separate Calibration manuals.

If the robot has Absolute Accuracy calibration, it is also recommended but not always needed to be calibrated 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 transmission.

Contents of the revolution counter memory are lost

If the contents of the revolution counter memory are lost, the counters must be updated as detailed in section

Updating revolution counters on page 254 . 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 robot is changed for other reachability, it needs to be recalibrated for new resolver values.

If the robot has Abslolute Accuracy calibration, it needs to be calibrated for new Absolute

Accuracy.



5.2. Calibration methods

5.2. Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied from ABB.

Types of calibration

Type of calibration

Description Calibration method

Standard calibration

Absolute Accuracy calibration

(optional)

The calibrated robot is positioned at home position, that is the axes positions (angles) are set to 0º.

Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery.

The file identifies the correct resolver/motor position corresponding to the robot home position.

From deliveries together with RobotWare 5.0.5 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

Calibration Pendulum

(standard method) or

Levelmeter calibration

(alternative method)

Based on standard calibration, and besides positioning the robot at home 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 data is found in the file absacc.cfg, supplied with the robot at delivery.

The file replaces the calib.cfg file and identifies motor positions as well as absacc-compensation parameters.

From deliveries together with RobotWare 5.0.6 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

A robot calibrated with AbsAcc 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

250




5.2. Calibration methods

Continued

Calibration methods

Each calibration method is detailed in a separate manual. Below is a brief description of the methods available.

Calibration Pendulum - standard method

Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB

6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

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 for Calibration Pendulum , which describes the method and the different routines further.

Levelmeter Calibration - alternative method

Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots, because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.

This method may, after calibration, require modifications in the robot program, and is therefore not recommended.

The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter

2000.

CalibWare - Absolute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy is used as a TCP calibration. The tool CalibWare guides through the calibration process and calculates new compensation parameters. This is further detailed in the application manual

Absolute Accuracy Calibware 2.0

.

If a service operation is done to a robot with 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 section


The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including Operating manual - Calibration Pendulum , which describes the method and the different routines further.



5.3. Calibration scales and correct axis position

5.3. Calibration scales and correct axis position

Introduction

This section specifies the calibration scale positions and/or correct axis position for all robot models.

Calibration scales, IRB 6620

The illustration below shows the positions of the calibration marks on all axes of the robot.

252 xx0600003096

C

D

A

B

E

F

Calibration scale, axis 1








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 etc. Positive directions are shown in the figure below.

This is normally handled by the robot calibration software.

Calibration movement directions, 6 axes

Note! The figure shows an IRB 7600, but 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



5.5. Updating revolution counters

5.5. Updating revolution counters

General

This section details how to perform a rough calibration of each robot axis, that is updating the revolution counter value for each axis, using the pendant.

Step 1 - Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter; manually running the robot to the calibration position.

Action Note

1. Select axis-by-axis motion mode.

3. When all axes are positioned, store the revolution counter settings.

2. Jog the robot to place the calibration marks within the tolerance zone.

Shown in section Calibration scales and correct axis position on page 252

.

Detailed in section:

Step 2 - Storing the revolution counter setting with the FlexPendant on page 254

(RobotWare 5.0).

Correct calibration position of axis 4 and 6

When running the robot to calibration position, it is extremely important to make sure that axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be calibrated at the wrong turn, resulting in wrong calibrated robot.

Make sure the axes are positioned according to the correct calibration values, not only according to the calibration marks. The correct values are found on a label, located either on the lower arm or underneath the flange plate on the base.

At delivery the robot 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 below 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 uneven gear ratio. This affects the following robots:

Robot variant

IRB 6620

Axis 4

Yes

Axis 6

No

If the calibration 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 calibration marks again (try both directions, if needed).

Step 2 - Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0).

254

Action

1. On the ABB menu, tap Calibration .

All mechanical units connected to the system are shown along with their calibration status.



Action

2. Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters .


5.5. Updating revolution counters

Continued en0400000771

3. 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.

4. 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 .

5. 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 ticked revolution counters and removes the tick from the list of axes.

6.

CAUTION!

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

See section Checking the calibration position on page 256 .



5.6. Checking the calibration position

5.6. Checking the calibration position

General

Check the calibration position 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 teach pendant.

Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero position.

Action Note

1. On ABB menu tap Program Editor.

2. Create a new program.

3. Use MoveAbsJ in the Motion&Proc menu.

4. Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,

9E9]]\NoEOffs, v1000, z50, Tool0

5. Run the program in manual mode.

6. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in

section Calibration scales and correct axis position on page 252

.

How to update the revolution counters is detailed in section

Updating revolution counters on page 254 .

Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.

Action Note

1. Tap Jogging in the ABB menu.

2. Tap Motion mode to choose group of axes to jog.

3. Tap axis 1-3 to jog axis 1, 2, or 3.

4. Manually run the robots axes to a position where the axis position value read on the

FlexPendant, is equal to zero.

5. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in section

Calibration scales and correct axis position on page 252 .

How to update the counters is detailed in section

Updating revolution counters on page 254

.


6 Decommissioning

6.1. Environmental information


6.1. Environmental information

Hazardous material

The table specifies some of the materials in the robot and their respective use throughout the product.

Dispose the components properly to prevent health or environmental hazards.

Material

Batteries, NiCad or Lithium

Copper

Cast iron / nodular iron

Steel

Neodymium

Plastic / rubber (PVC)

Oil, grease

Aluminium

Example application

Serial measurement board

Cables, motors

Base, lower arm, upper arm

Gears, screws, base-frame etc.

Brakes, motors

Cables, connectors, drive belts etc.

Gearboxes

Covers, sync. brackets

Oil and grease

Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do no dispose of oil and grease near lakes, ponds, ditches, down drains, or on to soil. Incineration must be carried out under controlled conditions in accordance with local regulations.

Also note that:

• Spills may form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired.

• Spillage may penetrate the soil causing ground water contamination.



6.1. Environmental information


7 Reference information

7.1. Applicable Safety Standards


7.1. Applicable Safety Standards

Standards, general

The robot is designed in accordance with the requirements of:

• EN ISO 10218-1: 2006 Robots for industrial environments - Safety requirements -

Part 1 Robot.

• EN 292-1 - Basic terminology.

• EN 292-2 - Technical principles.

• EN 418 - Emergency stop.

• EN 563 - Temperatures of surfaces.

• EN 954-1 - Safety related parts of control systems.

• EN ISO 60204-1: 2005 Safety of machinery - Electrical equipment of machines - Part

1 General requirements.

• EN 1050 - Principles for risk assessment.

• ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.

• DIN 19258 - Interbus-S, International Standard

Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:

• EN 953 - Fixed and moveable guards

• EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.

• EN 349 - Minimum gaps to avoid crushing of parts of the human body.

• EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.

• EN 1088 - Interlocking devices

• EN 999 - The positioning of protective equipment in respect of approach speeds of the human body.

• ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing systems.



7.2. Unit conversion

7.2. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity

Length

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 bar

1 N

1 Nm

1 L

3.28 ft

2.21 lb

100 kPa

0.738 lbf

0.738 lbf-tn

0.264 US gal

39.37 in

14.5 psi



7.3. Screw joints

7.3. Screw joints

General

This section details how to tighten the various types of screw joints on the robot.

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. Tighten to the torque specified in section

Tightening torque on page 262

below. 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 Art. no.

Molycote 1000 (molybdenum disulphide grease) 11712016-618



261


7.3. Screw joints

Continued

Tightening torque

262

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 tables below. 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.

• Always tighten the joint by hand, and never use pneumatical 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% !

The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Dimension

M2.5

M3

M4

M5

M6

Tightening torque (Nm)

Class 4.8, oil-lubricated

0.25

0.5

1.2

2.5

5.0

The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws.

M5

M6

M8

M10

M12

M16

M24

Dimension


(Nm)


6

10

24

47

82

200

725


(Nm)



(Nm)


-

-

34

67

115

290

960

-

-

40

80

140

340

1150

The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.

Dimension


Class 10.9, Molycote-lubricated



M8

M10

M12

28

55

96

35

70

120




7.3. Screw joints

Continued

Dimension





M16

M24

235

790

280

950

The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass .

Dimension

1/8

1/4

3/8

1/2

3/4


Nm - Nominal

12

15

20

40

70


Nm - Min.

8

10

15

30

55


Nm - Max.

15

20

25

50

90



7.4. Weight specifications

7.4. 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 high-lighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

Example

Below is an example of how a weight specification is presented, inside a procedure table:

Action Note

CAUTION!




7.5. Standard toolkit

7.5. Standard toolkit

General

All service (repairs, maintenance and installation) procedures contain 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 table below.

This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction.

Contents, standard toolkit

Qty Tool

1

1

1

1

1

1

1

1

1

2

1

1

Rem.

Ring-open-end spanner 8-19 mm

Socket head cap 5-17 mm

Torx socket no: 20-60

Box spanner set

Torque wrench 10-100 Nm

Torque wrench 75-400 Nm

Ratchet head for torque wrench 1/2

Hexagon-headed screw M10x100

Socket head cap no: 14, socket 40 mm bit L 100 mm

Socket head cap no: 14, socket 40 mm bit L 20 mm To be shortened to 12 mm





7.6. Special tools

7.6. 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 section Standard toolkit on page 265

, and of special tools, listed directly in the instructions and also gathered in this section.

Calibration equipment, Calibration Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

Description Art. no.

Note

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual.

Basic tools

The table below specifies the tools in the basic toolkit that are used for the current robot model. This toolkit is necessary primarly 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, motor ax 1

Lifting tool, motor ax 2, 3

Removal tool, motor M10x

Removal tool, motor M12x

Rotation tool

Standard toolkit (content described in section


)

Qty

1

1

1

1

2

2

2

1

2

2

Art. no.

3HAC12342-1

3HAC15520-1

3HAC15520-2

3HAC15521-1

3HAC15521-2

3HAC14459-1

3HAC026061-001

3HAC14972-1

Fits motors, axes 6.

-

Fits motors axes 1, 2 and 3.

3HAC17105-1

Lifting tool

266

The table below specifies the lifting 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, procedures .

Description

Lifting tool

Hoisting block

Lifting chain (used together with the hoisting block)

Support, base and gear axis 1

Qty Art. no.

3HAC026597-001

3HAC15535-1



Description

Lifting tool, gearbox axis 1

Lifting eye (used together with lifting tool

3HAC 15556-1)

Lifting tool, gearbox

Guide pins, M12x130

Guide pins, M16x

Lifting eye, M16

Lifting eye, M20

Crank

Qty


7.6. Special tools

Continued

Art. no.

3HAC15556-1

3HAC025333-005

3HAC025214-001

3HAC022637-001

3HAC14457-1



7.7. Lifting equipment and lifting instructions

7.7. Lifting equipment and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure.

The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored for later reference.


8 Spare parts and exploded views

8.1. Introduction



Definitions

This chapter specifies all spare parts and replacement articles of the robot.



8.2. Spare parts - cable harness

8.2. Spare parts - cable harness

Part list

Description

Material set, Cable harness

Manipulator harness IRB 6620

Connection plate

Frame bracket, conn.plate

Top cover, conn.box

Screw

Screw

Screw

Screw

Adapter, complete

Protection cover

Cable guide

SMB/BU cover

SMB/BU box

Push button guard


Screw

BU with buttons DSQC 563

Serial measurement unit DSQC633

Nut

Lock washer

Battery pack

Strap, Velcro

Screw

Cable protection

Cable, FB7-SMB 1.7

Protection screw

Washer

Nut

Cable sealing

Cover

Clip lock

Cover plate

Screw M6x16

Item.

Qty.

SparePart number

529

530

531

532

533

525

526

527

528

521

522

523

524

517

518

519

520

513

514

515

516

509

510

511

512

505

506

507

508

501

502

503

504

1

2

1

1

8

1

1

1

1

4

1

1

1

4

4

1

1

1

1

1

10

1

1

1

1

33

2

2

12

2

1

1

1

3HAC025054-001

3HAC025079-001

3HAC025080-001

3HAC025081-001

9ADA618-56

9ADA618-57

9ADA618-59

9ADA629-56

3HAC11774-3

3HAC13416-1

3HAC024286-001

3HAC024065-001

3HAC024063-001

3HAC6499-1

3HAC4813-1

9ADA618-44

3HAC16035-1

3HAC022286-001

9ADA290-1

3HAB3558-14

3HAC16831-1

3HAC12625-1

9ADA120-405

3HAC024972-001

3HAC15619-1

3HAC14024-1

3HAC17423-1

9ADA269-4

3HAC024542-001

3HAC025089-001

5217520-11

3HAC12129-1

9ADA618-56

270



Illustration 1






271



Continued

Illustration 2

272 xx0600003067



8.3. Spare parts - frame and base

8.3. Spare parts - frame and base

Parts list

Description

Base incl. frame, axis 1

RV 320C-191,35

Frame

Base

Screw

Stop pin

Loctite 243

Oil seal

Bearing grease

Screw

Washer

Screw

Serrated lock washer

O-ring

Magnetic plug

Bearing grease

Protection plug

Item.

113

114

115

116

109

110

111

112

105

106

107

108

101

102

103

104

Qty.

Part number

3

3

10

2

12

12

16

16

1

1

1

1

1

2 ml

1

10

3HAC026114-001

3HAC026178-001

3HAC026117-001

9ADA205-75

3HAC024014-001

3HAB7116-1

3HAC11581-4

3HAB3537-1

3HAB3409-86

3HAA1001-186

3HAB3409-74

3HAC026169-001

3HAB3772-97

3HAC16721-1

3HAB3537-1

3HAC4836-1



273


8.3. Spare parts - frame and base

Continued

Illustration

274 xx0600003061



8.4. Spare parts - wrist

8.4. Spare parts - wrist

Parts list

Description

Wrist

Wrist insulated

Rotational AC motor incl. Pinion

Gear unit Z2-3/5

Middle gear unit Z4-5/5

Gear wheel unit Z6/5

Support shaft inc. Bearing

Screw

Plain washer

Screw

Screw

Screw

Screw

Washer

Sealing

Cover right, with gasket

Screw

Magnetic plug

Lubrcating oil

Cover left

Damper ax.5

Screw

VK-cover

Screw

Ax.6 complete

Turning disc

RV 40E-81


Washer

Magnetic plug

Lubrcating oil

Screw

Axis 6 complete, insulated

Turning disc, insulated

RV 40E-81

Magnetic plug


Lubricating oil Kyodo Yushi TMO 150

Sync plate


Item.

Qty.


1.329

305

305.1

305.2

305.4

305.7

305.8

305.9

1.320

1.321

1.322

1.323

1.324

1.325

1.326

1.327

1.310

1.311

1.314

1.314

1.316

1.317

1.318

1.319

300

300

1.301

1.302

1.303

1.304

1.306

1

1

6

1

2

1

1

1

6

1

6

6

3

5

4

4

1

1

1

1

1

1

1

1

20

3HAC028475-001

3HAC031470-001

3HAC024782-004

3HAC024746-003

3HAC024715-003

3HAC024719-003

3HAC026318-001

9ADA183-37

9ADA312-7

9ADA624-56

9ADA624-56

9ADA183-39

3HAB7700-65

3HAA1001-632

3HAC024865-001

3HAC024841-003

9ADA618-56

2 3HAC16721-1

3200 ml 11712016-604

3HAC024672-004

3HAC024541-001

9ADA618-56

3HAA2166-23

3HAB3409-86

3HAC9744-2

3HAC9744-5

3HAC10828-10

1

8

3HAC15990-4

3HAA1001-172

2 2522122-1

300 ml 3HAC021469-001

305.15

8

350 1

350.1

1

350.1.2

1

3HAB7700-55

3HAC17255-2

3HAC17057-1

3HAC10828-10

350.1.13 2

350.2

1

350.5

350.7

2522122-1

3HAC14990-4

300ml 3HAC032140-001

1 3HAC16862-2


275



Continued

Description

Screw M4x8

Protection cover

Item.

350.8

350.9

Qty.

2

1


9ADA618-32

3HAC14263-1

276



Illustration






8.5. Spare parts - Upper arm

8.5. Spare parts - Upper arm

Parts list

Description Item.

Axis 3-4

Reduction gear RV-320E i=201

Screw

Washer

Rot AC motor incl. Pinion

Screw

Washer

Magnetic plug

Rot AC motor incl. Pinion

Wheel Unit ax.4

Screw

Plain washer

Screw

Washer

Parallel pin

Cover ax.4 with sealing

Gasket

Sealing

Screw

Loctite 243

Magnetic plug

219

220

Lubrcating oil 221

Lubrcating oil (Kyodo Yushi TMO 150) 222

217

217.1.2

217.2

218

205

206

207

216

201.8

202

203

204

200

201.1

201.3

201.4

201.5

201.6

201.7

Qty.


6

1

4

6

1

4

3

1

4

4

16

1

1

1

16

3HAC025576-001

3HAC023619-001

3HAB3409-69

3HAA1001-134

3HAC024771-003

3HAB3409-50

3HAB4233-1

3HAC16721-1

3HAC024782-003

3HAC024563-003

9ADA183-37

9ADA312-7

3HAB3409-71

3HAA1001-632

9ABA107-56

1

1

1

14

3HAC025196-002

3HAC025154-001

3HAA1001-628

9ADA618-56

14 ml 3HAB7116-1

2 3HAC16721-1

5700

2200

11712016-604

3HAC032140-001

278



Illustration


8.5. Spare parts - Upper arm




8.6. Spare parts - complete robot

8.6. Spare parts - complete robot

Parts list

Description

Revolution indicator ax. 4

Rotational AC motor incl. pinion

Rotational AC motor incl. pinion

Screw

Washer

Reduction gear RV-550E i=242,73

O-ring

Screw

Washer

Lubrcating oil

Lubrcating oil

Magnetic plug

Screw

Screw

Washer

Damper ax.3

Screw

Spring washer, conical

Screw

Washer

Sync plate

Washer

Screw

Lower arm

Plug, plastic

Item.

20

21

22

23

16

17

18

19

6

11

12

13

14

15

15.2

28

31

32

33

24

25

26

27

34

35

Qty.

1

1

1

8

4

16

16

2

4

4

20

20

1

1

8

8

1

1

24

24

4

4

6100

4100


3HAC026087-001

3HAC024512-003

3HAC024518-004

3HAB3409-50

3HAB4233-1

3HAC024316-001

3HAB3772-91

3HAB3409-71

3HAA1001-134

3HAC021469-001

3HAC021469-001

3HAC16721-1

9ADA618-56

3HAB3409-69

3HAA1001-134

3HAC12320-1

9ADA624-65

9ADA334-7

3HAB3409-84

3HAA1001-186

3HAC024859-001

3HAA1001-134

3HAB3409-69

3HAC023618-004

3HAC025824-001

280



Illustration








9 Circuit diagram


Overview

This chapter includes the circuit diagram for the robot.


9.1. Introduction


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9.1. Introduction


Index

A

Absolute Accuracy, calibration

251

B brake release unit, replacement

195

brakes testing function

24

C cabling between robot and controller

89

cabling, robot

89

calibrating roughly

254

calibration

Absolute Accuracy type

250

alternative method

251


251

marks/scales

252

rough

254

standard type

250

when to calibrate

249

calibration manuals

251

calibration position

254

checking

256

jogging to, FlexPendant

256

scales

252

calibration, Absolute Accuracy

251

CalibWare

250

complete arm system, replacement

166

connecting the robot and controller, cabling

89

Connection of external safety devices

14

D direction of axes

253

E enabling device

26

ESD damage elimination

35

sensitive equipment

35

wrist strap connection point

35

explanation, safety symbols

30

F

FlexPendant jogging to calibration position

256

MoveAbsJ instruction

256

updating revolution counters

254

foundation loads

47

requirements

48

G gearbox axis 6, replacement

244

Gravity Beta

71

H hold-to-run

26

I installation

3HAC027151-001 Revision: B mechanical stop axis 1

84

mechanical stop axis 3

87

inverted mounting

71

L


251

lifting equipment

264

loads on foundation

47

M mechanical stop axis 1

84

axis 3

87

motor axis 1, replacement

199


203


208


213


217


221

MoveAbsJ instruction

FlexPendant

256

N negative directions, axes

253

O oil change safety risks

36

operating conditions, robot

48

P position, robot

252

positive directions, axes

253

protection classes

48

R replacement brake release unit

195

complete arm system

166

gearbox axis 6

244

motor axis 1

199

motor axis 2

203

motor axis 3

208

motor axis 4

213

motor axis 5

217

motor axis 6

221

turning disk

175

requirements on foundation

48

restricting working range axis 1

84

working range axis 3

87

revolution counters storing on FlexPendant

254

updating

254

risk of tipping

53

robot operating conditions

48

protection class

48

storage conditions

48

weight

47

robot position

252

285

Index

S safety equipment mechanical stop

84

mechanical stop axis 3

87

signal lamp

120

Safety, service

14

safety, symbols

30

scales on robot

252

securing the robot to foundation, attachment screws

68

securing, base plate

64

securing, robot

68

special tools

266

stability

53

storage conditions, robot

48

suspended mounting

71

symbols, safety

30

sync marks

252

system parameter

Gravity Beta

71

T testing, brakes

24

tightening torque mechanical stop axis 1

85

tilted mounting

71

tools

Calibration Pendulum equipment

266

for service

266

turning disk replacement

175

U updating revolution counters

254

V

Validity and responsibility

14

W wall mounting

71

weight base plate

63

,

67

lower arm

188

motor

201

,

210

,

211

upper arm

182

,

184

weight, robot

47

working range restricting axis 1

84

restricting axis 3

87


ABB AB

Robotics Products

S-721 68 VÄSTERÅS

SWEDEN

Telephone: +46 (0) 21 344000

Telefax: +46 (0) 21 132592

ABB IRB 6620 - 150/2.2 Product Manual

Product manual

Articulated robot

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Decommissioning

7 Reference information

8 Spare parts and exploded views

9 Circuit diagram

5BCMFPGDPOUFOUT

Key Features

Related manuals

Frequently Answers and Questions

What is the payload capacity of the IRB 6620 - 150/2.2?

What is the reach of the IRB 6620 - 150/2.2?

What is the repeatability of the IRB 6620 - 150/2.2?

What are some of the key safety features of the IRB 6620 - 150/2.2?

What are some of the applications that the IRB 6620 - 150/2.2 is ideal for?

Table of contents

ABB IRB 6620 - 150/2.2 Product Manual

Product manual

Articulated robot

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Decommissioning

7 Reference information

8 Spare parts and exploded views

9 Circuit diagram

5BCMFPGDPOUFOUT

Key Features

Related manuals

Manfrotto

MVMXPROA4US

Brother

XL-5700

Brother

PR-620/620C/600II/600IIC

ABB

IRB 6660 - 130/3.1

ABB

IRB 6620

ABB

IRB 6620

ABB

IRB 120

ABB

MTD 500

ABB

IRB 460-110/2.4

ABB

IRB 4400/60

Omron

ZX-T Series CR_UGD4_XL

Omron

CR_UGD4_XXL1300H _R

Frequently Answers and Questions

What is the payload capacity of the IRB 6620 - 150/2.2?

What is the reach of the IRB 6620 - 150/2.2?

What is the repeatability of the IRB 6620 - 150/2.2?

What are some of the key safety features of the IRB 6620 - 150/2.2?

What are some of the applications that the IRB 6620 - 150/2.2 is ideal for?

Table of contents