ABB IRB 6620 Product Manual

ROBOTICS

Product manual

IRB 6620

Trace back information:

Workspace R18-1 version a9

Checked in 2018-03-22

Skribenta version 5.2.025

Product manual

IRB 6620 - 150/2.2

IRC5

Document ID: 3HAC027151-001

Revision: T

© Copyright 2006-2018 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's written permission.

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.


ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents


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

Product documentation ....................................................................................................................

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

9

14

16

1 Safety

1.1

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

1.1.1

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

1.1.2

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

1.2

Safety actions ...................................................................................................

1.2.1

Fire extinguishing ....................................................................................

1.2.2

Emergency release of the robot axes ..........................................................

1.2.3

Make sure that the main power has been switched off ....................................

1.3

Safety risks ......................................................................................................

1.3.1

Safety risks during installation and service work on robots ..............................

1.3.2

Moving robots are potentially lethal ............................................................

1.3.3

First test run may cause injury or damage ....................................................

1.3.4

Work inside the working range of the robot ..................................................

1.3.5

Enabling device and hold-to-run functionality ...............................................

1.3.6

Risks associated with live electric parts .......................................................

1.3.7

The unit is sensitive to ESD .......................................................................

1.3.8

Hot parts may cause burns .......................................................................

1.3.9

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

1.3.10 Brake testing ..........................................................................................

1.3.11 Safety risks during handling of batteries ......................................................

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

1.4

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

1.4.1

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

1.4.2

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

17

29

30

32

33

24

26

27

28

21

22

23

24

17

17

20

21

34

35

36

37

39

39

41

2 Installation and commissioning 47

2.1

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

2.2

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

2.3

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

2.4

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

2.4.1

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

2.4.2

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

2.4.3

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

2.5

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

2.5.1

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

2.5.1.1 Fitting the fork lift accessory ..........................................................

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

2.5.2

Lifting the robot with lifting and turning tool ..................................................

2.5.3

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

2.5.4

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

2.5.5

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

2.5.6

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

2.5.7

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

2.5.8

Setting the system parameters for a suspended or tilted robot .........................

2.5.9

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

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

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

2.6

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

2.6.1

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

2.6.2

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

2.6.3

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

77

79

81

82

66

66

69

72

57

61

65

66

47

48

54

57

87

91

96

104

105

106

106

107

109

Product manual - IRB 6620

3HAC027151-001 Revision: T

5



2.7

Foundry Plus Cable guard (option) .......................................................................

2.7.1

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

2.8

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

2.8.1

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

2.9

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

111

111

112

112

114

3 Maintenance 115

3.1

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

3.2

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

3.2.1

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

3.2.2

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

3.2.3

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

3.3

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

3.3.1

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

3.3.2


3.3.3


3.3.4


3.3.5


3.3.6


3.3.7

Inspecting, cable harness ........................................................................

3.3.8

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

3.3.9

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

3.3.10 Inspecting the additional mechanical stops .................................................

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

3.3.12 Inspecting, signal lamp ............................................................................

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

3.4

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

3.4.1

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

3.4.2

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

3.4.3


3.4.4


3.4.5


3.4.6


3.4.7


3.4.8

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

3.5

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

3.5.1

Cleaning the IRB 6620 ..............................................................................

157

160

163

166

169

173

173

141

144

146

148

149

149

151

154

122

125

127

129

131

134

137

139

115

116

116

117

119

120

120

4 Repair 177

4.1

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

4.2

General procedures ...........................................................................................

4.2.1

Performing a leak-down test ......................................................................

4.2.2

Mounting instructions for bearings .............................................................

4.2.3

Mounting instructions for seals ..................................................................

4.2.4

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

4.2.5

The brake release buttons may be jammed after service work .........................

4.3

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

4.3.1

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

4.3.2

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

4.3.3

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

4.4

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

4.4.1

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

4.4.2

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

4.4.3

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

4.4.4

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

4.5

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

4.5.1

Replacement of SMB unit .........................................................................

4.5.2

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

185

185

192

202

213

213

217

222

177

178

178

179

181

183

184

228

233

233

238

6 Product manual - IRB 6620




4.6

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

4.6.1

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

4.6.2

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

4.6.3


4.6.4


4.6.5

Replacement of motor, axis 5 , IRB 6620/6620LX ...........................................

4.6.6


4.7

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

4.7.1

Replacement gearbox axis 1 .....................................................................

4.7.2

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

4.7.3

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

4.7.4

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

242

242

247

253

260

265

270

277

277

286

294

299

5 Calibration 305

5.1

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

5.1.1

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

5.1.2

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

5.1.3

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

5.2

Synchronization marks and axis movement directions .............................................

5.2.1

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

5.2.2

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

5.3

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

5.4

Calibrating with Axis Calibration method ...............................................................

5.4.1

Description of Axis Calibration ..................................................................

5.4.2

Calibration tools for Axis Calibration ...........................................................

5.4.3

Installation locations for the calibration tools ...............................................

5.4.4

Axis Calibration - Running the calibration procedure ......................................

5.5

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

5.6

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

5.7

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

319

319

322

324

326

332

333

334

305

305

306

309

310

310

312

313

6 Decommissioning 335

6.1

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

6.2

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

335

337

7 Reference information 339

7.1

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

7.2

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

7.3

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

7.4

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

7.5

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

7.6

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

7.7

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

339

341

342

345

346

347

349

8 Spare part lists 351

8.1

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

351

9 Circuit diagram 353

9.1

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

353

Index 355




7

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Overview of this manual


About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot

Usage

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel

Prerequisites

This manual should be used during:

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

• maintenance work

• repair work and calibration

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

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

Organization of chapters

The manual is organized in the following chapters:

Chapter Contents

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

Installation and commissioning

Required information about lifting and installation of the robot.

Maintenance

Repair

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 on the robot. Based on available spare parts.

Calibration procedures and general information about calibration.

Calibration

Decommissioning

Reference information

Environmental information about the robot and its components.

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



Continues on next page

9



Continued

References

Revisions

Chapter Contents

Spare parts and exploded views

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

Circuit diagrams Reference to the circuit diagram for the robot.

Reference

Product specification - IRB 6620

Product manual, spare parts - IRB 6620

Circuit diagram - IRB 6620 / IRB 6620LX

Operating manual - General safety information i

Product manual - IRC5

IRC5 with main computer DSQC 639.

Product manual - IRC5

IRC5 with main computer DSQC1000.

Operating manual - IRC5 with FlexPendant

Document ID

3HAC025861-001

3HAC049109-001

3HAC025090-001

3HAC031045-001

3HAC021313-001

3HAC047136-001

3HAC050941-001

Operating manual - Calibration Pendulum

Operating manual - Service Information System

Application manual - Additional axes and stand alone controller

Technical reference manual - Lubrication in gearboxes

3HAC16578-1

3HAC050944-001

3HAC051016-001

3HAC042927-001

Technical reference manual - System parameters 3HAC050948-001 i

Application manual - CalibWare Field 5.0

3HAC030421-001

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

-

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.


10





Continued

Revision

C

D

E

F

G

Description

This revision includes the following additions and/or changes:

• Section What is an emergency stop?

added to chapter Safety‘

• Section Maintenance schedule in chapter Maintenance: Intervals for inspection activities and oilchanges have been revised

• Section Maintenance schedule in chapter Maintenance: Overhaul of robot is new

• Section Maintenance schedule in chapter Maintenance: The information about Service Information System (SIS) has been updated

• Section Maintenance schedule in chapter Maintenance: Intervals for replacement of battery pack changed

• Section Expected lifetime in chapter Maintenance: The lifetime of certain parts has been revised

• Section Cleaning of robot updated


• Section Lifting and turning tool added to the Installation chapter.

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

• Updated spare part numbers in lists for cable harness and wrist.


• Added oil levels for tilted robots, see

Inspecting the oil level in axis-1 gearbox on page 120

, and

Inspecting the oil level in axis-2 gearbox on page 122 .

• Corrected item number reference in part list, see Spare parts - Upper arm in Product manual, spare parts - IRB 6620 .

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

Circuit diagram on page 353 .

• List of standards updated, see

Applicable standards on page 339 .

The chapter Safety updated with:

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

Safety signals in the manual on page 39 .

• New safety labels on the manipulators, see

Safety symbols on product labels on page 41 .

• Revised terminology: robot replaced with manipulator .

This revision includes the following updates:

• Maximum deviation changed, see

Securing the base plate on page 82 .

• Updated instructions for replacing motor axis 6 on Foundry Plus robots.

This revision includes following additions and/or changes:

• Removed information about lubricating attachment screws, section

Inspecting the additional mechanical stops on page 141

.





11


Continued

Revision

H

J

K

L

M

N

Description


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

How to read the product manual on page 16

.

• Robot designations are adjusted in sub-headings in section

Robot transportation precautions on page 48 .

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

Screw joints on page 342

.

• Added

Safety risks during handling of batteries on page 36

.

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


• Added information about how to check oil level and change oil in the axis-1 gearbox of a suspended robot, see


and

Changing oil, axis-1 gearbox on page 151 .

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


• All data about type of lubrication in gearboxes is moved from the manual to a separate lubrication manual, see

Type and amount of oil in gearboxes on page 149 .

• Added section

Inspection of air hoses (Foundry Prime) on page 148

.


• Corrected location of label for lifting, see

Inspecting the information labels on page 137

.

• Spare part number for wrist (standard) was wrong. Has been corrected.

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


• New instruction for inspection of oil level.

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

Scrapping of robot on page 337 .

• Spare parts and exploded views are not included in this document but delivered as a separate document. See Product manual, spare parts - IRB 6620 .


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


• Changed dimension of cable holder carrier screw, see

Replacement of cable harness, upper end on page 192 .

• Added tightening torque for R1.SMB and 7th axis connector, ses

Replacement of cable harness, lower end (axes 1-2) on page 185

.

• Minor corrections.


• Split fork lift accessory instruction in two sections.

• Improvements Foundry Plus (retrofit sets) added throughout the manual. New wrist cover and improved sealing on arm house cover, and more.





12





Continued

Revision

P

Q

R

S

T

Description



• Description about the revolution indicator.

• Changed filling oil plug to inspection oil plug in inspection of level axis

3.

• Information updated and added in the calibration chapter.


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

Calibration on page 305 .

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

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


• Corrections due to updates in terminology.


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

• Information about minimum resonance frequency added.

• Bending radius for static floor cables added.

• Updated list of applicable standards.

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

• Section

Start of robot in cold environments on page 114

added.

• Updated information regarding replacement of brake release board.

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

• Definition of reference calibration clarified.


• Information added about fatigue to Axis Calibration tool, see

Calibration tools for Axis Calibration on page 322

.

• Added sections in

General procedures on page 178

.

• Safety restructured.

• New spare part number brake release board (was DSQC563,

3HAC16035-1)

• Corrections of required equipment, see

Mechanically restricting the working range of axis 1 on page 107

.

• Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previously created reference calibration values.

• Information about myABB Business Portal added.

• Added Nickel in Environmental information.




13

Product documentation


Categories for user documentation from ABB Robotics

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

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

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

.

Product manuals

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

• Safety information.

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

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

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

• Calibration.

• Decommissioning.

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

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

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe reference information for robotics products, for example lubrication, the RAPID language, and system parameters.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals . An application manual can describe one or several applications.

An application manual generally contains information about:

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

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

• How to install included or required hardware.

• How to use the application.

• Examples of how to use the application.


14





Continued

Operating manuals

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




15

How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material, and so on. The references are read as described below.

References to figures

The procedures often include references to components or attachment points located on the manipulator/controller. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown.

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

The table below shows an example of a reference to a figure from a step in a procedure.

8.

Action

Remove the rear attachment screws, gearbox.

Note/Illustration

Shown in the figure Location of gearbox on page xx .

References to required equipment

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

The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list.

The table below shows an example of a reference to a list of required equipment from a step in a procedure.

3.

Action

Fit a new sealing, axis 2 to the gearbox.

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 the chapter

Safety on page 17

.

Illustrations

The robot is illustrated with general figures that does not take painting or protection type in consideration.

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




1 Safety

1.1.1 Limitation of liability

1 Safety

1.1 General safety information

1.1.1 Limitation of liability

Limitation of liability

Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with.

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

In particular, liability cannot be accepted if injury/damage has been caused for any of the following reasons:

• Use of the robot in other ways than intended.

• Incorrect operation or maintenance.

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

• When instructions for operation and maintenance are not followed.

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

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

• Foreign objects.

• Force majeure.

Nation/region specific regulations

To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.

To be observed by the supplier of the complete system

The integrator is responsible that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

When integrating the robot with external devices and machines:

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

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





17

1 Safety


Continued

The integrator of the final application is required to perform an assessment of the hazards and risks (HRA).

Note

The integrator is responsible for the safety of the final application.

Safe access

The robot system shall be designed to allow safe access to all areas where intervention is necessary during operation, adjustment, and maintenance.

Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations.

Safety zones, which must be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

Turntables or the like should be used to keep the operator out of the robot's working space.

A safety fence is recommended to ensure safeguarded space. Sufficient space must be provided around the manipulator to protect those working with or on it from hazards such as crushing.

The fence or enclosure must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see the section

Robot motion in the Product specification ).

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

Safe handling

Users shall not be exposed to hazards, including slipping, tripping, and falling hazards.

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. If any of the buttons do not stop all the robot workcell motion, each emergency stop button must be marked, if more than one is provided, to indicate its designated safety function.

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


18




1 Safety


Continued

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

CAUTION

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




19

1 Safety

1.1.2 Protective stop and emergency stop

1.1.2 Protective stop and emergency stop

Overview

The protective stops and emergency stops are described in the product manual for the controller.

20




1 Safety

1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO

2

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




21

1 Safety

1.2.2 Emergency release of the robot axes

1.2.2 Emergency release of the robot axes

Description

In an emergency situation, the brakes on a robot axis can be released manually by pushing a brake release button.

How to release the brakes is described in the section:

•

Manually releasing the brakes on page 79 .

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

Increased injury

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

DANGER

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways.

Make sure no personnel is near or beneath the robot.

22




1 Safety

1.2.3 Make sure that the main power has been switched off

1.2.3 Make sure that the main power has been switched off

Description

Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these personal injuries, switch off the main power on the controller before proceeding work.

Note

Switch off all main power switches in a MultiMove system.

Spot welding cabinet

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

DANGER

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




23

1 Safety

1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

Requirements on personnel

Only persons who know the robot and are trained in the operation and handling of the robot are allowed to maintain the robot. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, repair, or use the robot.

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

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

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

General risks during installation and service

The instructions in the product manual must always be followed.

Never turn the power on to the robot before it is properly fixed and bolted to its foundation/support.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to remove the power cable to the controller.

If the robot is installed at a height, hanging, or other than standing directly on the floor, there may be additional risks than those for a robot standing directly on the floor.

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

Never use the robot as a ladder, which means, do not climb on the controller, motors, or other parts during service work. There is a risk of slipping because of the high temperature of the motors and oil spills that can occur on the robot. There is also a risk of the robot being damaged.

To avoid damaging the product, make sure that there are no loose screws, turnings, or other parts inside the product after work has been performed.

Safety risks during operational disturbances

Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.





1 Safety

1.3.1 Safety risks during installation and service work on robots

Continued

If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been tested and approved by ABB. The installation and/or use of such products could negatively affect the structural properties of the robot and as a result of that affect the active or passive safety operation. ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. An external safety function can interact with other machines and peripheral equipment via this interface. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment for the robot installation.

Allergenic material

See

Environmental information on page 335

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




25

1 Safety

1.3.2 Moving robots are potentially lethal

1.3.2 Moving robots are potentially lethal

Description

Any moving robot is a potentially lethal machine.

When running, the robot may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the robot.

Safe handling

1

2

3

Action Note

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

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

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

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

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

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

26




1 Safety

1.3.3 First test run may cause injury or damage

1.3.3 First test run may cause injury or damage

Description

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

Safe handling

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

DANGER

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

1

2

3

4

5

6

7

Action

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

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

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

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

Install all safety equipment properly.

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

If maintenance or repair has been done, pay special attention to the function of the part that was serviced.

Collision risks

CAUTION

When programming the movements of the robot, always identify potential collision risks before the first test run.




27

1 Safety

1.3.4 Work inside the working range of the robot

1.3.4 Work inside the working range of the robot

WARNING

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

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

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

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

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

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

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

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

WARNING

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

28




1 Safety

1.3.5 Enabling device and hold-to-run functionality

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

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

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

Note

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

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

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

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

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

Hold-to-run function

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

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




29

1 Safety

1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

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

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

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

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

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

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

Voltage related risks, IRC5 controller

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

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

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

• The main supply/main switch

• The transformers

• The power unit

• The control power supply (230 VAC)

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

• The drive unit (400/700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

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

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

• Additional connections.

Voltage related risks, robot

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

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

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

VAC).





1 Safety

1.3.6 Risks associated with live electric parts

Continued

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

Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.




31

1 Safety

1.3.7 The unit is sensitive to ESD

1.3.7 The unit is sensitive to ESD

Description

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

Safe handling

1

2

3

Action Note

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

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

• Product manual - IRC5

• Product manual - IRC5 Panel Mounted

Controller

Use an ESD protective floor mat.

Use a dissipative table mat.

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

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

32




1 Safety

1.3.8 Hot parts may cause burns

1.3.8 Hot parts may cause burns

Description

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

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

Safe handling

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

Wait until the potentially hot component has cooled if it is to be removed or handled in any other way.

Do not put anything on hot metal surfaces, e.g. paper or plastic.




33

1 Safety

1.3.9 Safety risks related to pneumatic/hydraulic systems

1.3.9 Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Note

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

Residual energy

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

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

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

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

Splashed oil may cause injury or fire.

Safe design

Gravity may cause any parts or objects held by these systems to drop.

Dump valves should be used in case of emergency.

Shot bolts should be used to prevent tools, etc., from falling due to gravity.

34




1 Safety

1.3.10 Brake testing

1.3.10 Brake testing

When to test

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

How to test

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

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

2 Switch the motor to the MOTORS OFF.

3 Inspect and verify that the axis maintains its position.

If the robot does not change position as the motors are switched off, then the brake function is adequate.




35

1 Safety

1.3.11 Safety risks during handling of batteries

1.3.11 Safety risks during handling of batteries

Description

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

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

Note

Appropriate disposal regulations must be observed.

Safe handling

Use safety glasses when handling the batteries.

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

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

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

Operating temperatures are listed in

Pre-installation procedure on page 57

.

36




1 Safety

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

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

Description

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

Note

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

Note

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

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Safe handling

Warning Description Elimination/Action

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

90 °C.

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

Hot oil or grease

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

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

Allergic reaction

Possible pressure build-up in gearbox

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

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





37

1 Safety

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

Continued

Warning

Do not overfill

Description Elimination/Action

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

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the robot from moving freely.

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

After filling, verify that the level is correct.

Do not mix types of oil

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

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

Warm oil drains quicker than cold oil.

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

Heat up the oil

Specified amount depends on drained volume

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

After filling, verify that the level is correct.

Contaminated oil in gear boxes

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

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

38




1 Safety

1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all dangers that can arise when doing the work described in the user manuals. Each danger consists of:

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

• A brief description of what will happen if the operator/service personnel do not eliminate the danger.

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

Danger levels

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

Symbol xx0200000022 xx0100000002

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Significance

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

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

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

xx0200000024 xx0100000003

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

ELECTROSTATIC

DISCHARGE (ESD)

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

xx0200000023





39

1 Safety

1.4.1 Safety signals in the manual

Continued

Symbol Designation

NOTE

Significance

Describes important facts and conditions.

xx0100000004

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

xx0100000098

40




1 Safety

1.4.2 Safety symbols on product labels

1.4.2 Safety symbols on product labels

Introduction to labels

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

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

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

Note

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

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

Types of labels

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

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

Symbols on safety labels on page 41

.

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

French).

Symbols on safety labels

Symbol xx0900000812 xx0900000811

Description

Warning!

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

Caution!

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

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

Prohibition

Used in combinations with other symbols.

xx0900000839




41


1 Safety


Continued

Symbol xx0900000813

Description

See user documentation

Read user documentation for details.

Which manual to read is defined by the symbol:

• No text: Product manual .

• EPS: Application manual - Electronic Position Switches .

Before disassemble, see product manual xx0900000816

Do not disassemble

Disassembling this part can cause injury.

xx0900000815

Extended rotation

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

xx0900000814 xx0900000808

Brake release

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


42




Symbol

1 Safety


Continued

Description

Tip risk when loosening bolts

The robot can tip over if the bolts are not securely fastened.

xx0900000810 xx1500002402

Crush

Risk of crush injuries.

xx0900000817





43

1 Safety


Continued

Symbol Description

Heat

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

!

xx1300001087

1 xx0900000819

3

4

5

2

6

Moving robot

The robot can move unexpectedly.

xx1000001141

2

4

3

1 xx1500002616


44




Symbol

1 Safety


Continued

Description

Brake release buttons xx0900000820 xx1000001140 xx0900000821

Lifting bolt

Chain sling with shortener xx1000001242

Lifting of robot xx0900000822

Oil

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

xx0900000823

Mechanical stop xx0900000824





45

1 Safety


Continued

Symbol Description

No mechanical stop xx1000001144

Stored energy

Warns that this part contains stored energy.

Used in combination with Do not disassemble symbol.

xx0900000825

Pressure

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

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827

Do not step

Warns that stepping on these parts can cause damage to the parts.

xx1400002648

46




2 Installation and commissioning

2.1 Introduction


2.1 Introduction

General

This chapter contains assembly instructions and information for installing the IRB

6620 at the working site.

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

6620, such as:

• Load diagram

• Permitted extra loads (equipment), if any

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


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

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

Safety on page 17

before performing any installation work.

Note

If the IRB 6620 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work.

For more information see:





47


2.2 Robot transportation precautions

2.2 Robot transportation precautions

General

This section describes ABB approved transportation precautions for ABB robots.

CAUTION

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

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

Method 1 - recommended method

Transportation according to method 1 is strongly recommended by ABB.

xx0800000030

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

• Always remove the tool before transportation of the robot.

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

Risk of tipping/stability on page 65 .

• Always read and follow the instructions in section

Pre-installation procedure on page 57

Method 2 - transportation with a tool mounted to the robot

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

1 is not possible.







Continued

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

• Always read and follow the instructions in section

Securing the robot with a transport support on page 54

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

Transport position with a transport support on page 51 .

• Always use the recommended transport support described in sub section

Recommended transport support on page 52 .





49



Continued

IRB 6620

D

C

A

B xx0800000036

C

D

A

B

Transport Support

Hexagon socket head cap screw M10x50

Threaded bar M10x280

Nut M10


50






Continued

Transport position with a transport support

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

IRB 6620 xx0800000041





51



Continued

Recommended transport support

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

IRB 6620 xx0800000039


52




IRB 6620



Continued xx0800000038




53


2.3 Securing the robot with a transport support

2.3 Securing the robot with a transport support

General

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

DANGER

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


54




Fitting the transport support

Illustration for fitting the transport support



Continued

B

A xx1400000944

Fitting the transport support

1

Action

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

(A) in figure.

Note

Do not tighten the screw.

See attachment point for the specific robot in the section





55




Continued

2

Action Note

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


CAUTION

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

3

4

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


See attachment point for the specific robot in the section

Transport position with a transport support on page 51

Tighten all the attachment screws, (A) and

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

CAUTION

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

This can seriously damage the robot.

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

Manually releasing the brakes on page 79

56





2.4.1 Pre-installation procedure

2.4 Unpacking

2.4.1 Pre-installation procedure

Introduction

This section is intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot.

Prerequisites for installation personnel

Installation personnel working with an ABB product must:

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

• conform to all national and local codes.

Checking the pre-requisites for installation

1

2

3

Action

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

Remove the packaging.

Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damages are found.

4

5

6

7

8

9

10

11

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

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

Weight, robot on page 58

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

Storage conditions, robot on page 60

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

Operating conditions, robot on page 60

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

•

Loads on foundation, robot on page 58

•

Protection classes, robot on page 60

•

Requirements, foundation on page 59

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

Risk of tipping/stability on page 65

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

On-site installation on page 66

Install required equipment, if any.

•

Signal lamp (option) on page 105





57



Continued

Weight, robot

The table shows the weight of the robot.

The weight does not include the weight of the DressPack.

Robot model

IRB 6620

Weight

900 kg

Note

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

The weight does not include the weight of the DressPack.

Loads on foundation, robot

The illustration shows the directions of the robots stress forces.

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

T xy

F z

F xy

T z xx1100000521

F xy

F z

T xy

T z

Force in any direction in the XY plane

Force in the Z plane

Bending torque in any direction in the XY plane

Bending torque in the Z plane

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

Note

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







Continued

WARNING

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

Floor mounted

Force

Force xy

Force z

Torque xy

Torque z

Endurance load (in operation)

± 7.3 kN

11.0 ±2.0 kN

± 18.0 kNm

± 4.4 kNm

Max. load (emergency stop)

± 15.5 kN

11.0 ±3.7 kN

± 37.2 kNm

± 10.4 kNm

Suspended

Force

Force xy

Force z

Torque xy

Torque z

Endurance load (in operation)

± 7.3 kN

- 11.0 ±2.0 kN

± 18.0 kNm

± 4.4 kNm

Max. load (emergency stop)

± 15.5 kN

- 11.0 ±3.7 kN

± 37.2 kNm

± 10.4 kNm

Requirements, foundation

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

Requirement Value

Flatness of foundation surface

0.3 mm

Maximum tilt 15°

Note

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

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

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

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

The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°.

Contact ABB for further information about acceptable loads.





59



Continued

Requirement

Minimum resonance frequency

Value Note

22 Hz

Note

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

The value is recommended for optimal performance.

Due to foundation stiffness, consider robot mass including equipment.

i

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

i

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

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

Storage conditions, robot

The table shows the allowed storage conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient temperature (less than 24 hrs)

Maximum ambient humidity

Value

-25° C

+55° C

+70° C

95% at constant temperature

(gaseous only)

Operating conditions, robot

The table shows the allowed operating conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient humidity

Value

+5° C

+50° C

Max. 95% at constant temperature

Protection classes, robot

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

Protection type

Manipulator, protection type Standard

Protection class

IP 54 i i

Manipulator, protection type Foundry Plus IP 67

The upper arm, including the wrist, has protection class IP 67.

60





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

1473

854

2204





61



Continued

Suspended mounted

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

2204 1473

854 858 xx0600002907


62






Continued

Floor mounted in 15° angle

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

5

1

°

A

B

1171

693 1019

2369 xx0600002908

A

B

Note ! Maximum tilt angle is 15°

Intersection between base and axis 1 center





63



Continued

Turning radius - floor mounted

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

xx0600002909

Type of motion

2

3

4

5

6

Axis

1

Type of motion

Rotation motion

Arm motion

Arm motion

Wrist motion

Bend motion

Turn motion

Range of movement

+ 170° to - 170°

+ 140° to - 65°

+ 70° to - 115°

+ 300° to - 300°

+ 130° to - 130°

+ 300° to - 300° default

Note

Limitations with dresspack

Limitations with dresspack

Max. ±96 revolutions ¹

¹ The default working range can be extended by changing parameter values in the software. Option Advanced Motion is required.

64





2.4.3 Risk of tipping/stability

2.4.3 Risk of tipping/stability

Risk of tipping

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

The shipping position is the most stable position.

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

Shipping and transportation position

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

xx0600002935

WARNING

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





2.5.1.1 Fitting the fork lift accessory

2.5 On-site installation

2.5.1 Lifting the robot with fork lift accessory

2.5.1.1 Fitting the fork lift accessory

Required equipment

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

Equipment

Fork lift pocket set

Fork lift truck -

Art. no.

3HAC025040-003

Note

The fork lift accessory set contains:

• fork lift pocket

3HAC025528-001, with CE-

Marking fitted (4 pcs)

• attachment screws

M20x60 Steel 8.8-A3F (8 pcs)

• Drawing Fork lift accessory set

• manual Directions for use - Fork lift accessory for

IRB 6620, 6640, 460

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

Preparations before fitting the fork lift pockets

1

Action Note

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

Note

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

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

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

Note

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


66


xx0600002935





Continued

Action

3

DANGER

Turn off all:

• electric power supply

• hydraulic pressure supply

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

Note

Attachment points on the robot

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

xx0600002910

A

B

Fork lift pocket

Attachment screw M20x60 quality 8.8 (2 pcs x4)





67



Continued

Fitting the fork lift accessory set

1

Action Note

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

Tightening torque: 300 Nm

Note

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

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

xx0600002930

A Fork lift pocket (4 pcs)

B Attachment screw M20x60 quality 8.8 (2 pcs x4)

68





2.5.1.2 Lifting the robot with fork lift truck

2.5.1.2 Lifting the robot with fork lift truck

General

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

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


Equipment

Fork lift accessory

Fork lift truck

Art. no.

3HAC025040-003

Note

Lifting the robot with fork lift truck

1

Action

Make sure that the robot is in shipping position!

Note

Note

No load is permitted on the robot!

2

3

DANGER

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

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





69



Continued

4

Action

Insert fork lift forks into the pockets.

CAUTION

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

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

Note

IRB 6620 xx0600002911

IRB 6640

0°

1 Ax3

Ax2

45°

A x5

80° xx0600003401

IRB 460 xx1000001159


70






Continued

5

Action

Remove the attachment bolts securing the robot to the foundation.

Note

6

7

8

CAUTION

The IRB 6620 robot weighs 900 kg.

All lifting accessories used must be sized accordingly!

Carefully lift the robot.

WARNING

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

Move the robot slowly to its new position.

Note

Move the robot with low speed!

Secure the robot to the foundation 9

DANGER

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

10 Remove the fork lift accessories.




71


2.5.2 Lifting the robot with lifting and turning tool

2.5.2 Lifting the robot with lifting and turning tool

The lifting and turning tool

The lifting and turning tool 3HAC025792-001is used for lifting and turning of the

IRB 6620.

xx0900000325

A

B

C

D

E

Upper lifting beam

Chains

Lifting eye

Lower lifting beam

Lifting hold (Left and Right)


72




Lifting position




1

Action Note

Jog the robot axis to a position suitable for lifting

Lifting position according to figure.




73




Continued

Turning procedure

Fitting the lifting and turning tool

The figure shows the lifting and turning tool fitted to the robot.

xx0900000327

F

G

D

E

I

H

A

B

C


74

Lifting accessories for forks

Robot base

Lifting eye upper beam

Attachment bolts in robot base

Distribution beam

Attachment bolts for distribution beam

Lifting chains

Chain block lifting eye

Upper beam






Continued

J Lifting hooks

Turning the robot

Action Information

1

DANGER

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

Also read the safety sections:

•

Safety risks related to pneumatic/hydraulic systems on page 34

•

Lifting the robot with lifting and turning tool on page 72

•

Safety risks during installation and service work on robots on page 24

2

3

4

5

6

7

Fit the four lifting accessories for forks on the robot base

Tightening torque 300Nm

Fit the lifting tool

3HAC025792-001 to the robot base using the eight attachment screws

Tightening torque 90Nm

Lift the upper beam using a overhead crane

Attach the upper beam to the lower beam using the lifting chains.

Lift slowly until the chains are tensioned. Make sure that no cabling is damaged while lifting.

Attach the chain block to the upper beam lifting eye.

Note

Use a suitable chain block for minimum lifting weight

500 kg and with chain length minimum 3 m.





75



Continued

8

Action

Use lifting slings to secure the robot shown in figure.

Information

9

10

11

Lift slowly until the load moves. Lift until the distance between the floor and robot is at least 350 mm.

Turn the robot using the chain block.

If the robot is to be moved to the installation location, use a forklift.

xx0900000332

76





2.5.3 Lifting robot with roundslings

2.5.3 Lifting robot with roundslings

General

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

Sling specification

Sling type

Roundsling, robot

Roundsling, upper arm

Roundsling, upper arm

Qty

4 pcs

2 pcs

1 pc

Lifting capacity

1 000 kg

1 000 kg

1 000 kg

Length / Note

2.5 m

Note!

Do not stretch!

2 m

Secures against rotation.

2 m

Note!

Do not stretch!

Secures against rotation.

Lifting with roundslings

1

2

3

Action Note

Position robot in a secure transport position.

Attach lifting eye bolts in the rear M20 holes.

Shown in figure

Attachment points on page 78

.

Attach roundslings to robot according to figure

Attachment points on page 78 .

4

Note

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

5

6

7

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

Shown in the figure


.

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


.

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


.

8

CAUTION

The IRB 6620 robot weighs 900 kg.






77


2.5.3 Lifting robot with roundslings

Continued

Action

9

WARNING

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

Note

Attachment points

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

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

78 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)





2.5.4 Manually releasing the brakes

2.5.4 Manually releasing the brakes

Introduction to manually releasing the brakes

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

Location of brake release unit

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

xx0600002936

Releasing the brakes

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

1

Action Note

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

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

Supplying power to connector R1.MP

on page 80

.

Buttons are shown in figure

Location of brake release unit on page 79 .

2

DANGER

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways.

Make sure no personnel is near or beneath the robot.





79


2.5.4 Manually releasing the brakes

Continued

3

Action

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

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

Note

Supplying power to connector R1.MP

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

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

Action Note

1

DANGER

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

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

xx0600002937

80





2.5.5 Lifting the base plate

2.5.5 Lifting the base plate


Equipment

Lifting eye, M16

Lifting slings

Hole configuration

Article number

3HAC14457-4

Note

3 pcs

Length: approx. 2 m xx0200000096

A Attachment holes for lifting eyes (x3)

Lifting, base plate

Action Note

1

2

3

CAUTION

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

Fit lifting eyes in specified holes.

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

Shown in figure

Hole configuration on page 81

.

CAUTION

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





2.5.6 Securing the base plate

2.5.6 Securing the base plate

Base plate, dimensions

D G

F

B

B

H

2x R525

598,31

560,85

487,01

(Ø 800)

12x M24

Ø1 A

455

243,5

A

A

E

0

73,84

111,30

C C

2x 50x45º

857,3

1020

4x48

0.3

Common Zone

E, F, G, H

A

A-A

Ø 45P7

Ø1.5

3x45º

13

(2)

(48)

B-B

(4x)

6,3

(2)

1,6

3x45º

(2)

13

3x R1

45

K

7 c

47

0

+0,5

52,5º

0,25 c

(2)

(2x R22,5)

3x4

3x 90º

C-C D

1,6 xx1000001053

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


82







A Four holes for alternative clamping, 4x Ø18





83



Continued

Base plate, orienting grooves and leveling bolts

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

B A

B

A

B

B

A xx1500000312

A

B

Orienting grooves (3 pcs)

Levelling bolts, attachment holes (4 pcs)


84






Continued

Base plate, guide sleeve holes

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

A xx0300000045

A Guide sleeve holes (2 pcs)


Equipment

Base plate

Standard toolkit

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

-

Article number Note

3HAC12937-9 Includes

• guide sleeves, 3HAC12937-3

• levelling screws, 9ADA120-79

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

Content is defined in section

Standard tools on page 346 .

These procedures include references to the tools required.

Base plate

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

1

Action

Make sure the foundation is levelled.

Note




85




Continued

Action Note

2

CAUTION

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

3

4

5

6

7

8

9

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

Lift the base plate to its mounting position.

Shown in figure

Base plate, orienting grooves and leveling bolts on page 84 .

Detailed in section

on page 81 .

Lifting the base plate

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

Attachment holes: 16 pcs.

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

Shown in figure

Base plate, orienting grooves and leveling bolts on page 84 .

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

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

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

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

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

86





2.5.7 Orienting and securing the robot

2.5.7 Orienting and securing the robot

General

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

Illustration, robot fitted to base plate

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

xx0600002933

C

D

A

B

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

Orienting grooves in the robot base and in the base plate

Levelling screws.

Note!

Remove before the robot base is fitted!

Base plate attachment screws

Attachment screws

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

Suitable screws, lightly lubricated:

Quality:

Suitable washer:

Tightening torque:

M24 x 100

Quality 8.8

Thickness: 4 mm

Outer diameter: 44 mm

Inner diameter: 25 mm

725 Nm





87



Continued

Securing the robot

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

1

2

3

Action

Lift the robot.

Note

See section

Lifting robot with roundslings on page 77 .

Move robot to the vicinity of its installation location.

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

Shown in figure

Base plate, guide sleeve holes on page 85 .

Note

One of the guide sleeve holes is elongated!

4

5

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

Fit the bolts and washers in the base attachment holes.

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

Specified in

Attachment screws on page 87 .

Shown in figure

Illustration, robot fitted to base plate on page 87 .

Note

Lightly lubricate screws before assembly!

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


88






Continued

Hole configuration, base

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

R400

4 x 15°

4 x 37.5° xx0600002932





89



Continued

Cross section, guide sleeve hole

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

xx0600002934

90





2.5.8 Setting the system parameters for a suspended or tilted robot

2.5.8 Setting the system parameters for a suspended or tilted robot

General

The robot is configured for mounting parallel to the floor, without tilting, on delivery.

The method for mounting the robot in a suspended (upside down) or tilted position is basically the same as for floor mounting, but the system parameters that describe the mounting angle (how the robot is oriented relative to the gravity) must be re-defined.

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.

Note

The allowed mounting positions are described in the product specification for the robot. The requirements on the foundation are described in

Requirements, foundation on page 59

.

System parameters

Note

The mounting angle must be configured correctly in the system parameters so that the robot system can control the movements in the best possible way. An incorrect definition of the mounting angle will result in:

• Overloading the mechanical structure.

• Lower path performance and path accuracy.

• Some functions will not work properly, for example Load Identification and

Collision detection .

Gravity Beta

If the robot is mounted upside down or on a wall (rotated around the y-axis), then the robot base frame and the system parameter Gravity Beta must be redefined.

Gravity Beta should then be π (+3.141593) if the robot is mounted upside down

(suspended), or ±π/2 (±1.570796) if mounted on a wall.

The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians.





91



Continued

Gravity Alpha

The Gravity Alpha is a positive rotation direction around the x-axis in the base coordinate system. The value is set in radians.

Note

The system parameter Gravity Alpha is not supported for all robot types. It is not supported for IRB 140, IRB 1410, IRB 1600ID, IRB 2400, IRB 4400, IRB 6400R,

IRB 6400 (except for IRB 6400 200/2.5 and IRB 6400 200/2.8), IRB 6600, IRB

6650, IRB 6650S and IRB 7600 (except for IRB 7600 325/3.1).

If the robot does not support Gravity Alpha , then use Gravity Beta along with the recalibration of axis 1 to define the rotation of the robot around the x-axis.

Note

The parameter is supported for all robots on track when the system parameter

7 axes high performance motion is set, see Technical reference manual - System parameters .

Gamma Rotation

Gamma Rotation defines the orientation of the robot foot on the travel carriage

(track motion).

Mounting angles and values

The parameter Gravity Beta (or Gravity Alpha ) specifies the mounting angle of the robot in radians. It is calculated in the following way.

Gravity Beta = A° x 3.141593/180 = B radians , where A is the mounting angle in degrees and B is the mounting angle in radians.

Example of position

Floor mounted

Tilted mounting

Suspended mounting

Mounting angle (A°)

0°

15°

180°

Gravity Beta

0.000000 (Default)

0.261799

3.141593


92






Continued

Examples of mounting angles tilted around the Y axis ( Gravity Beta ) xx0600003144

A

B

C

Floor mounted

Tilted mounting, mounting angle 15°.

Suspended mounting, mounting angle 180°.





93



Continued

Examples of mounting angles tilted around the X axis ( Gravity Alpha )

The following illustration shows the IRB 120, but the same principle applies for all robots.

xx1500000532

3

4

Pos

1

2

Mounting angle

0° (Floor mounted)

45° (Tilted)

90° (Wall)

-90° (Wall)

Gravity Alpha

0

0.785398

1.570796

-1.570796

Note

For suspended robots (180°), it is recommended to use Gravity Beta instead of

Gravity Alpha .


94






Continued

Defining the parameter in the IRC5 software

The value of the system parameters that define the mounting angle must be redefined when changing the mounting angle of the robot. The parameters belong to the type Robot , in the topic Motion .

How to calculate a new value is detailed in

Mounting angles and values on page 92 .

The system parameters are described in Technical reference manual - System parameters .

The system parameters are redefined in the Configuration Editor , in RobotStudio or on the FlexPendant.




95


2.5.9 Fitting equipment on robot

2.5.9 Fitting equipment on robot

General

The robot features mounting holes for additional equipment.

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

Note

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

Illustration, fitting of extra equipment on lower arm

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

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

xx0600002940


96











97



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.

xx0600002941


98











99



Continued

Illustration, fitting of extra equipment on frame

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

xx0600002947


100











101



Continued

Illustration, fitting on turning disc

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

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.

Turning disk type 1


102







Turning disk (type 2) for robot version IRB 6620 Foundry Plus.

Fastener quality

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

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





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

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

General

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

CAUTION

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

References

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

• Operating manual - IRC5 with FlexPendant

Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot.

104





2.5.11 Signal lamp (option)

2.5.11 Signal lamp (option)

Description

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

Installation

See the assembly instruction delivered with the signal lamp.

Function

The lamp is active in MOTORS ON mode.

Further information

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




105


2.6.1 Axes with restricted working range

2.6 Restricting the working range

2.6.1 Axes with restricted working range

General

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

The working range of the following axes may be restricted:

• Axis 1, hardware (mechanical stop) and software.

• 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.

Note

Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures.

106





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

Mechanical stops, axis 1

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

xx0600002938

C

D

A

B

Movable mechanical stop

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

Fixed mechanical stop

Mechanical stop pin axis 1





107



Continued


Equipment, etc.

Movable mechanical stop set, axis 1

(+15°/-7.5°)

Article number

3HAC025204-003

Note

Includes:

• one stop (+15°/ -7.5°),

3HAC025366-001

• one stop (+7.5°/ -15°),

3HAC025367-001

• attachment screws and washers

• document for movable mech.stop, 3HAC025204-

002

Standard toolkit

Technical reference manual - System parameters

-

-

Article number is specified in section

References on page 10 .

Installation, mechanical stops axis 1

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

Action Note

1

DANGER

Turn off all:

• electric power supply to the robot

• hydraulic pressure supply to the robot

• air pressure supply to the robot

Before entering the robot working area.

2

3

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

Mechanical stops, axis 1 on page 107

.

Tightening torque: 120 Nm.

Adjust the software working range limitations

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

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

4

WARNING

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

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

108






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

xx0600002973

A

B

Mechanical stop pin, axis 3

Attachment screw and washer


Equipment, etc.

Mechanical stop set, axis 3

Standard toolkit -

Art. no.

3HAC025290-003

Note

Includes:

• one mechanical stop pin,

3HAC025092-001.

• attachment screw and washer.

• document for Mech stop pin,

3HAC025409-001.


Standard tools on page 346

.




109




Continued

Equipment, etc.

Technical reference manual - System parameters

-

Art. no.

Note

Art. no. is specified in section


Installation, mechanical stops axis 3

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

Action Note

1

DANGER

2

3

Turn off all:





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


Shown in the figure

Mechanical stops, axis 3 on page 109

Note

The software working range limitations

(system parameters) must be redefined to correspond to the changes in the mechanical limitations of the working range (+70°/ -

90°).

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

4

WARNING

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

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

110





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

2.7 Foundry Plus Cable guard (option)

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

Introduction

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

Separate instructions for IRB 140, 4600, 1600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found on the DVD delivered with the Cable guard, article number 3HAC035933-001.




111


2.8.1 Robot cabling and connection points

2.8 Electrical connections

2.8.1 Robot cabling and connection points

Introduction

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

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

Main cable categories

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

Cable category

Robot cables

Description

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

Specified in the table

Robot cables on page 112 .

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

The customer cables also handle databus communication.

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


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

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


Robot cables

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

Cable sub-category

Robot cable, power

Robot cable, signals

Description Connection point, cabinet

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

XS1

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

XS2

Connection point, robot

R1.MP

R1.SMB

Robot cable, power

Cable

Robot cable, power: 7 m




Art. no.

3HAC026787-001

3HAC026787-002

3HAC026787-003

3HAC026787-004


112





2.8.1 Robot cabling and connection points

Continued

Robot cable, signals

Cable

Robot cable signal, shielded: 7 m




Art. no.

3HAC7998-1

3HAC7998-2

3HAC7998-3

3HAC7998-4

Bending radius for static floor cables

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

A

B xx1600002016

A

B

Diameter

Diameter x10

Grounding and bonding point on manipulator

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

xx1500001603




113


2.9 Start of robot in cold environments

2.9 Start of robot in cold environments

Introduction

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

Problems with starting the robot

Event message from Motion Supervision

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

1

2

3

Action

Turn off Motion Supervision.

Start the robot.

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

Note

Robot stopping with other event message

Use this procedure if the robot is not starting.

1

Action

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

Note

The speed can be regulated with the

RAPID instruction VelSet .

Adjusting the speed and acceleration during warm-up

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

Work cycles

3 Work cycles

5 Work cycles

5 Work cycles

5 Work cycles

More than 5 Work cycles

AccSet

20, 20

40, 40

60, 60

100, 100

100, 100

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

Max.

If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up.

114




3 Maintenance

3.1 Introduction

3 Maintenance


Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB

6620.

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

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

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

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


Observe all safety information before conducting any service work.

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

Safety on page 17

before performing any service work.

Note

If the IRB 6620 is connected to power, always make sure that the IRB 6620 is connected to protective earth before starting any maintenance work.






115

3 Maintenance

3.2.1 Specification of maintenance intervals

3.2 Maintenance schedule and expected component life

3.2.1 Specification of maintenance intervals

Introduction

The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 6620:

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

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

• SIS: specified by the robot's SIS (Service Information System). A typical value is given for a typical work cycle, but the value will differ depending on how hard each part is run. The SIS used in M2004 is further described in the

Operating manual - Service Information System .

Overhaul

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

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

Contact your local ABB Customer Service to get more information.

116




3 Maintenance

3.2.2 Maintenance schedule

3.2.2 Maintenance schedule

General

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

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

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

Expected component life on page 119

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

•

Inspection activities on page 120

•

Replacement/changing activities on page 149

•

Cleaning activities on page 173

Activities and intervals, standard equipment

The following table specifies the required maintenance activities and intervals.

Maintenance activity

Cleaning

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Change

Equipment

Robot

Oil level in axis-1 gearbox






Robot harness

Information labels

Dampers

Mechanical stop

Oil in axis-1 gearbox

Change Oil in axis-2 gearbox

Interval

Cleaning the IRB 6620 on page 173

Every 12 months.

Every 12 months.

Every 12 months.

Every 12 months.

Every 12 months.

Every 12 months.

Every 12 months i

.

Every 12 months.

Every 12 months.

Every 12 months.

First change when DTC

• 6,000 hours

ii

reads:

Second change when DTC

ii

• 24,000 hours reads:

Following changes:

• Every 24,000 hours.


• 6,000 hours ii reads:


ii


Following changes:






117

3 Maintenance

3.2.2 Maintenance schedule

Continued

Maintenance activity

Change

Change

Equipment



Interval


ii



ii


Following changes:


Every 24,000 hours.

Change

Change


Oil in axis-6 gear

Every 24,000 hours.


• 6,000 hours

ii

reads:


• 24,000 hours

ii

reads:

Following changes:


Overhaul Robot Every:

• 40,000 hours .

Replacement Battery pack, measurement system of type RMU101 or

RMU102 (3-pole battery contact)

36 months or battery low alert iii

Replacement Battery pack, measurement system with 2-pole battery contact, e.g. DSQC633A

Battery low alert iv i

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

Expected component life on page 119 .

ii iii

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

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced.

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

See the replacement instruction for more details.

iv The battery low alert (38213

Battery charge low ) is displayed when remaining backup capacity

(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with

FlexPendant for instructions.

Activities and intervals, optional equipment

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

Note Maintenance activity

Inspection

Inspection

Equipment

Signal lamp

Interval

Every:

12 months

Mechanical stop axis 1 and 3

Every:

12 months

118




3 Maintenance

3.2.3 Expected component life

3.2.3 Expected component life

General

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

Expected component life - protection type Standard

Component

Cable harness

Normal usage i

Expected life

40,000 hours ii

Note

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Cable harness

Extreme usage iii

20,000 hours

ii

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Gearboxes iv

40,000 hours i

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

ii

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

iii

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

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

Robotics Service team for more information.

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




119

3 Maintenance

3.3.1 Inspecting the oil level in axis-1 gearbox

3.3 Inspection activities

3.3.1 Inspecting the oil level in axis-1 gearbox

Location of gearbox

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

xx0600002958

A

B

C

Oil plug, filling

Oil plug, inspection

Oil plug, draining


Equipment

Lubricating oil

Standard toolkit


-

Art. no.

See


Note

Note

Do not mix with other oils!




Inspecting the oil level in axis-1 gearbox

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

Action Note

1

WARNING

Handling gearbox oil involves several safety risks.

Before proceeding, please read the safety information in the section

Safety risks during work with gearbox lubricants (oil or grease) on page 37

.





3 Maintenance


Continued

Action Note

2

3

4

5

DANGER

Turn off all:




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

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

Open the oil plug, inspection .

Measure the oil level.

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

Required oil level for tilted robots: 15-20 mm below the oil plug hole.

Shown in figure

Location of gearbox on page 120 .

A

6 Adjust the oil level, if required.

7 Refit the oil plug.

B

C xx1400002785

A Oil plug hole

B Required oil level

C Gearbox oil

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

Type of lubrication in gearboxes on page 149 .

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


Tightening torque:24 Nm




121

3 Maintenance



Location of gearbox on floor mounted robot

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

The following figure shows the robot mounted on the floor.

xx0600002959

A

B

C

Oil plug, vent hole

Oil plug, filling and inspection

Oil plug, draining

Location of gearbox on suspended mounted robot

The following figure shows suspended mounted robot.

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

xx0600002960


122




3 Maintenance


Continued

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.,

Lubricating oil

Standard toolkit


-

Art. no.

Note

See

Type and amount of oil in gearboxes on page 149

.

Note!







Action Note

1

WARNING

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

Safety risks during work with gearbox lubricants (oil or grease) on page 37 .

2

3

4

DANGER

Turn off all:





Make sure that the oil temperature is +25°C

±10°C.

Open the oil plug, filling and inspection .


Shown in the figure

Location of gearbox on floor mounted robot on page 122 .





123

3 Maintenance


Continued

5

Action


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

Required oil level for tilted robots: 40-45 mm below the oil plug filling hole. Note! Not the oil plug inspection hole.

Note

6

7

Adjust the oil level, if required.

Refit the oil plug.

A

B

C xx1400002785

A Oil plug hole


C Gearbox oil



Filling of oil is detailed further in the section

Filling, oil on page 155

.


124




3 Maintenance




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

xx0600002961

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit


-

Art. no.

Note

See


Note!









125

3 Maintenance


Continued



Action Note

1

WARNING



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


Detailed in the section

Synchronization marks and synchronization position for axes on page 310 .

3

DANGER

Turn off all:





4

5

6


±10°C.


Open the oil plug, inspection .


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

Shown in the figure


A



B

C xx1400002785

A Oil plug hole


C Gearbox oil



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

Filling, oil on page 159 .


126




3 Maintenance




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

xx0600002962

A

B


Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit


-

Art. no.

See


Note



.






127

3 Maintenance


Continued



Action Note

1

WARNING



2 Move the robot to the calibration position.

This is detailed in section

Synchronization marks and synchronization position for axes on page 310

.

3

4

5

6

DANGER

Turn off all:






±10°C.

Open the oil plug, filling and inspection


Required oil level: 0-10 mm

.


Shown in the figure

Location of gearbox on page 127

.

A



B

C xx1400002785

A Oil plug hole


C Gearbox oil




Filling, oil on page 161

.


128




3 Maintenance




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

xx0600002963

A

B


Oil plug, draining


Equipment etc.

Lubricating oil

Standard toolkit


-

Art. no.

See


.

Note






Action Note

1

WARNING




2

3

Move the robot upper arm to a horizontal position.

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




129


3 Maintenance


Continued

Action

4

DANGER

Turn off all:





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

±10°C.

Note

6 Open the oil plug, filling and inspection .

7 Measure the oil level.

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


Shown in the figure




xx0500002222




Filling, oil, axis 5 on page 164 .


130




3 Maintenance




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

xx0600002964

A

B

C

Type 1

Axis-6 gearbox


Oil plug, draining


Equipment

Lubricating oil

-

Art. no.

See


Note

Standard toolkit







Action Note

1

WARNING




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




131


3 Maintenance


Continued

Action Note

3

DANGER

Turn off all:





4

5

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


Open the oil plug, filling and inspection .

A xx1300000244

6

7

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

Open the oil plug, draining .

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

Note

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

8

9

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

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

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

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

C xx1400002786

Note

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

A

B

A Oil plug hole


C Gearbox oil





3 Maintenance


Continued

10

Action

Adjust the oil level, if required.

11

12

Refit the oil plugs.

WARNING

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

Note



.

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





133

3 Maintenance

3.3.7 Inspecting, cable harness

3.3.7 Inspecting, cable harness

Location of cable harness, axes 1-6

The axes-1-6 cable harness is shown below.

The figure shows the lower routing of the cable harness.

xx0600002970

C

D

E

A

B

F

G

H

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)


134




3 Maintenance


Continued

The figure shows the upper routing of the cable harness.

xx0600003078

F

G

D

E

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)


Visual inspection, no tools are needed.

Inspecting cable harness, axes 1-6

Use this procedure to inspect cable harness of axes 1-6.

Action Note

1

DANGER

Turn off all:







135


3 Maintenance


Continued

2

3

4

5

6

Action

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

Check the connectors at the base .

Note

Check the cables.

Shown in figure

Location of cable harness, axes 1-6 on page 134

Shown in figure


Check the metal clamps on the robot.

Shown in figure


Replace the cable harness if wear or damage is detected!

Detailed in section:


Replacement of cable harness, upper end on page 192

136




3 Maintenance

3.3.8 Inspecting the information labels

3.3.8 Inspecting the information labels

Location of labels

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

Safety symbols on product labels on page 41 .

xx0600002980

C

E

G

A

B

Warning label concerning high temperature (4 pcs)

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

Warning label concerning brake release

Instruction label concerning lifting

Serial no. from rating label





137

3 Maintenance

3.3.8 Inspecting the information labels


D

F

G

I

H

Warning label concerning risk of tipping

Label for calibration

Serial no. from rating label

UL-label

AbsAcc information sign

Required tools and equipment

Visual inspection, no tools are required.

Inspecting, labels

Action Note

1

DANGER

Turn off all:




2

3

Inspect the labels, located as shown in the figures.

Replace any missing or damaged labels.

Article numbers for the labels and plate set is specified in

Spare part lists on page 351 .

138




3 Maintenance

3.3.9 Inspecting the axis-1 mechanical stop pin

3.3.9 Inspecting the axis-1 mechanical stop pin

WARNING

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

Switch is used.

WARNING

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

Location of mechanical stop pin

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

xx0600002972

A

B


Fixed mechanical stop


Visual inspection, no tools are required.





139

3 Maintenance

3.3.9 Inspecting the axis-1 mechanical stop pin

Continued

Inspecting, mechanical stop pin

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

Action Note

1

DANGER

Turn off all:




2 Inspect the axis-1 mechanical stop pin.

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

Note

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

140




3 Maintenance

3.3.10 Inspecting the additional mechanical stops

3.3.10 Inspecting the additional mechanical stops

Location of mechanical stops

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

Additional mechanical stops are not provided for axis 2.

xx0600002938

C

D

A

B

Additional stop, axis 1

Attachment screws and washers (2 pcs)

Fixed stop






141

3 Maintenance



A

B


Attachment screw and washer


Equipment etc.

Article number

Mechanical stop set, axis 1 3HAC025204-003

Mechanical stop set, axis 3 3HAC025290-003

Standard toolkit -

Note

Includes:

• Stop +15°/-7.5°

• Stop +7.5°/-15°

• Attachment screws plus washers

• Document for movable mechanical stop

Includes:

• Mechanical stop pin

• Attachment screw and washer

• Document for mechanical stop pin



.


142




3 Maintenance


Continued

Inspecting, mechanical stops

Use this procedure to inspect the additional mechanical stops.

Action Note

1

DANGER

Turn off all:




2

3

4

Make sure no additional stops are damaged.

Shown in figure

Location of mechanical stops on page 141 .

Make sure the stops are properly attached.

Correct tightening torque, additional mechanical stops:

• Axis 1 = 120 Nm.

• Axes 2 and 3 = 115 Nm

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

Correct attachment screws:

• Axis 1: M12 x 40, quality 12.9.

• Axis 3: M6 x 16

Article number is specified in

Required equipment on page 142 .




143

3 Maintenance

3.3.11 Inspecting the damper on axes 2-5

3.3.11 Inspecting the damper on 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

Damper axes 2-3

Damper axis 5

Standard toolkit

Spare part/ art. no.

3HAC12320-1

3HAC024541-001

3HAC15571-1

Note




144




3 Maintenance

3.3.11 Inspecting the damper on axes 2-5

Continued

Inspection, dampers

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

Action Note

1

DANGER

Turn off all:





2

3

4

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

Check attachment screws for deformation.

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

Shown in the figure

Location of dampers on page 144 .

Art. no. is specified in

Required equipment on page 144

.




145

3 Maintenance

3.3.12 Inspecting, signal lamp

3.3.12 Inspecting, signal lamp

Location of signal lamp

The signal lamp is located as shown in this figure.

xx0600003071

C

D

A

B

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.



.



146




3 Maintenance

3.3.12 Inspecting, signal lamp

Continued

Inspecting, signal lamp

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

1

Action

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

Note

2

DANGER

Turn off all:





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

• Checking whether the signal lamp is broken.

If so, replace it.

• Checking cable connections.

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

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



.




147

3 Maintenance

3.3.13 Inspection of air hoses (Foundry Prime)

3.3.13 Inspection of air hoses (Foundry Prime)


Equipment, etc.

Leak detection spray

Pressure gauge

Cut off valve

Procedure

-

-

-

Art. no.

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

1

2

3

4

5

Action Note

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

Recommended pressure:

0.2-0.3 bar

Close the cut off valve.

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

The time is < 5 seconds:

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

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

Remove the leak testing equipment.

Pressurize by opening the cut off valve.

Spray suspected leak areas with leak detection spray.

Note

Bubbles indicate a leak.

6 When the leak is localized: correct the leak.

148




3 Maintenance

3.4.1 Type of lubrication in gearboxes

3.4 Replacement/changing activities

3.4.1 Type of lubrication in gearboxes

Introduction

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

Type and amount of oil in gearboxes

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

.

Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information.

For ABB personnel: Always check ABB Library for the latest revision of the manual

Technical reference manual - Lubrication in gearboxes , in order to always get the latest information of updates about lubrication in gearboxes. A new revision will be published on ABB Library immediately after updates.

Location of gearboxes

The figure shows the location of the gearboxes.

xx0600002977





149

3 Maintenance

3.4.1 Type of lubrication in gearboxes

Continued

D

E

F

A

B

C

Gearbox, axis 1

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 4

Gearbox, axis 5

Gearbox, axis 6

Equipment

Equipment

Oil dispenser

Nipple for quick connect fitting, with o-ring

Note

Includes pump with outlet pipe.

Use the suggested dispenser or a similar one:

• Orion OriCan article number 22590

(pneumatic)

150




3 Maintenance

3.4.2 Changing oil, axis-1 gearbox

3.4.2 Changing oil, axis-1 gearbox

Location of oil plugs

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

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

xx0600002958

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil

Oil collecting vessel

Oil exchange equipment

Standard toolkit -

Art. no.

See


.

-

3HAC021745-001

Amount Note

See


.

Note


Capacity: 8,000 ml.


Special tools on page 347

.







151

3 Maintenance


Continued

Draining oil, axis-1 gearbox

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

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

Art. no. for the kit is specified in


Action Note

1

DANGER

Turn off all:




2

WARNING



3

4

5

6

If the robot is suspended: lift down the robot from its inverted position and secure it on the floor.

Collect drained oil in an oil vessel.

Remove quicker!

oil plug, filling in order to drain oil

Vessel capacity is specified in


.

Shown in figure

Location of oil plugs on page 151 .

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

Note

CAUTION

Drain as much oil as possible. See


.

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

7 Refit the oil plug, draining .


152




3 Maintenance


Continued

Filling oil, axis-1 gearbox

Use this procedure to fill gearbox axis 1 with oil.

Action

1

DANGER

Turn off all:




Note

2

WARNING




.

3

4

Open the oil plug, filling.

Shown in figure

Location of oil plugs on page 151

.

Refill the gearbox with clean lubricating oil.

The correct oil level is detailed in section


.



.

5

Note

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

6 Refit the oil plug, filling.





153

3 Maintenance



Location of oil plugs

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

The figure shows both floor and suspended mounted robot.

Note that the holes are used differently depending on how the robot is mounted!

xx0600002983

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See


Oil collecting vessel -


3HAC021745-001

Standard toolkit -

Amount

See


Note

Note!

Do not mix with other oil types!

Capacity: 5,000 ml.



.




154




Draining, oil

Filling, oil

3 Maintenance


Continued

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

When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in


Action Note

1

DANGER

Turn off all:





2

WARNING



3

4

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 oil plugs on page 154 .



.

CAUTION

Note


Safety risks during work with gearbox lubricants

(oil or grease) on page 37

.

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

Refit the oil plug.


Use this procedure to fill oil into the axis-2 gearbox.



Action Note

1

DANGER

Turn off all:









155

3 Maintenance


Continued

Action Note

2

WARNING




3

4

Remove the oil plug for filling and the oil plug for inspection .

Shown in the figure

Location of oil plugs on page 154

.




.



5

Note

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



156




3 Maintenance




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

xx0600002961

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See


.

Oil exchange equipment 3HAC021745-001


Standard toolkit

-

-

Amount Note

See


Note!

Do not mix with other oil types!



.

Capacity: 3,000 ml.






157


3 Maintenance


Continued

Draining, oil

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



1

Action Note

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

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

2

DANGER

Turn off all:





3

WARNING



.

4

5

6

Remove the oil plug, filling .

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

Shown in the figure




.

CAUTION

Note



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

Refit the oil plug.



158




Filling, oil

3 Maintenance


Continued

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



Action Note

1

DANGER

Turn off all:





2

WARNING




.

3

4

Remove the oil plug, filling.

Shown in the figure


.




.



5

Note







159

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

Art. no.

See


.



Standard toolkit

-

-

Amount

See


.

Note



.

Capacity: 6,000 ml.



.

Draining, oil

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



Note

1

Action

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





Filling, oil

3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:





3

WARNING



4

5

6

7


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

Shown in the figure




.

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



.

Refit the oil plug, draining.


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



Action Note

1

DANGER

Turn off all:





2

WARNING






161


3 Maintenance


Continued

3

4

Action




.

Refit the oil plug, filling.

Note

Shown in the figure


.




162




3 Maintenance




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

xx0600002963

A

B

Oil plug, filling/inspection

Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See




Standard toolkit

-

-

Amount

See


Note


Special tools on page 347 .

Capacity: 4,000 ml.



Draining, oil, axis 5

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



1

Action

Move the robot to its calibration position.

Note

This puts the oil plug draing in the right position.





163

3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:





3

4

5

6

WARNING




.


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

Shown in the figure


.



Refit the oil plug, draining.


Filling, oil, axis 5

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



1

Action

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

Note

2

WARNING




.

3

DANGER

Turn off all:






164




3 Maintenance


Continued

4

5

Action Note




Shown in the figure


.



Refit the oil plug, filling.





165

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.

xx0600002964

A

B

C

Gearbox axis 6

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See



3HAC021745-001

Oil collecting vessel -

Standard toolkit -

Amount

See


.

Note

Note




.

Vessel capacity:

500 ml



Draining, oil, axis 6

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



1

Action

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

Note

Shown in the figure






3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:





3

4

5

WARNING




.

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

Refit the oil plug, filling .



.


Filling, oil, axis 6

The procedure below details how to fill oil into the gearbox, axis 6.



Action Note

1

DANGER

Turn off all:





2

WARNING




.

3

4

Remove the oil plug, filling.

Shown in the figure


.




.







167

3 Maintenance


Continued

5

6

Action

Note


Note


Type of lubrication in gearboxes on page 149 .

Refit the oil plug.

Inspect the oil level.




168




3 Maintenance

3.4.8 Replacing the SMB battery

3.4.8 Replacing the SMB battery

Note

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or

RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.

For an SMB board with 2-pole battery contact, the typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended for longer production breaks with a battery shutdown service routine. See Operating manual - IRC5 with

FlexPendant for instructions.

WARNING

See instructions for batteries,

Safety risks during handling of batteries on page 36

.

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.

H

G

A

B

C

D1

D2

F

E xx0600002982

A

B

C

Attachment screws

SMB/BU unit (complete)

Velcro strap





169

3 Maintenance


Continued

F

G

H

D1

D2

E

Battery pack (2-pole battery contact)


SMB/BU box

Connection point, battery cable

SMB (Serial measurement board)

BU unit (Brake release unit)


Note

There are two variants of SMB units and batteries. One with 2-pole battery contact and one with 3-pole battery contact. The variant with the 3-pole battery contact has longer lifetime for the battery.

It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact!

Equipment, etc.

Battery pack

Standard toolkit

Circuit diagram -

-

Spare part no.

For spare part no.

see:

•

Spare part lists on page 351

Note

Battery includes protection circuits. Only replace with a specified spare part or an ABBapproved equivalent.



See chapter

Circuit diagram on page 353

.

Removing, battery

Use this procedure to remove the SMB battery.

1

Action

Move the robot to its calibration position.

Note

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

2

DANGER

Turn off all:





170




3 Maintenance


Continued

3

Action Note xx0200000023

WARNING

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

The unit is sensitive to ESD on page 32

4 Remove SMB/BU box by unscrewing the attachment screws.

CAUTION

Clean cover from metal residues before opening.

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

5

6

7

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

Remove the velcro strap that holds the battery.

Remove the SMB battery.

Battery includes protection circuits. Only replace with a specified spare part or with an ABB- approved equivalent.

Shown in figure

Location of SMB battery on page 169 .

Refitting, battery

Use this procedure to refit the SMB battery.

Action

1

DANGER

Turn off all:




2

Note xx0200000023

WARNING

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





171


3 Maintenance


Continued

3

4

5

Action

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

Note



Shown in figure

Location of SMB battery on page 169

.

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

Shown in figure

Location of SMB battery on page 169

.

Update the revolution counter.

Detailed in chapter Calibration section

Updating revolution counters on page 313

.

6

DANGER

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

First test run may cause injury or damage on page 27 .

172




3 Maintenance

3.5.1 Cleaning the IRB 6620

3.5 Cleaning activities

3.5.1 Cleaning the IRB 6620

WARNING

Turn off all electrical power supplies to the manipulator before entering its work space.

General

To secure high uptime it is important that the IRB 6620 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works.

Different cleaning methods are allowed depending on the type of protection of the

IRB 6620.

Note

Always verify the protection type of the robot before cleaning.

Oil spills

Oil spills from gearboxes

Use the following procedure if any oil spills are detected that can be suspected to originate from a gearbox.

1 Inspect that the oil level in the suspected gearbox is according to the recommendations, see

Inspection activities on page 120 .

2 Write down the oil level.

3 Inspect the oil level again after, for example, 6 months.

4 If the oil level is decreased then replace the gearbox.

Oil spills discolors painted surfaces

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

Note

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

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.

• Always use cleaning equipment as specified. Any other cleaning equipment may shorten the life of the robot.

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

• Never point the water jet at connectors, joints, sealings, or gaskets.

• Do not use compressed air to clean the robot.




173


3 Maintenance


Continued

• Never use solvents that are not approved by ABB to clean the robot.

• Do not spray from a distance closer than 0.4 m.

• Do not remove any covers or other protective devices before cleaning the robot.

Cleaning methods

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

i

Protection type

Standard

Foundry Plus

Cleaning method

Vacuum cleaner

Yes

Wipe with cloth Rinse with water

Yes

Yes. With light cleaning detergent.

Yes. It is highly recommended that the water contains a rust-prevention solution and that the manipulator is dried afterwards.

Yes. With light cleaning detergent or spirit.

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

High pressure water or steam

No

Yes i

.

It is highly recommended that the water and steam contains rust preventive, without cleaning detergents.

Perform according to section

Cleaning with water and steam on page 174 .

Cleaning with water and steam

Instructions for rinsing with water

ABB robots with protection types Standard , Foundry Plus , Wash , or Foundry Prime can be cleaned by rinsing with water (water cleaner).

1

I

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 700 kN/m

2

(7 bar)

I

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum flow: 20 liters/min

I

Typical tap water pressure and flow

Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus , Wash , or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner.

2

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 2500 kN/m

2

(25 bar)

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum water temperature: 80° C

1

2

See

Cleaning methods on page 174

for exceptions.

See

Cleaning methods on page 174

for exceptions.





Cables

3 Maintenance


Continued

Movable cables need to be able to move freely:

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

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




175


4 Repair

4.1 Introduction

4 Repair


Structure of this chapter

This chapter describes all repair activities recommended for the IRB 6620 and any external unit.

It is made up of separate procedures, each describing a specific repair activity.

Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials.

WARNING

Repair activities not described in this chapter must only be carried out by ABB.

Otherwise damage to the mechanics and electronics may occur.


The details of the equipment required to perform a specific repair activity are listed in the respective procedures.

The details of equipment are also available in different lists in the chapter

Reference information on page 339

.


There are general safety information and specific safety information. The specific safety information describes the danger and safety risks while performing specific steps in a procedure. Make sure to read through the chapter

Safety on page 17

before commencing any service work.

Note

If the IRB 6620 is connected to power, always make sure that the IRB 6620 is connected to earth before starting any repair work.






177

4 Repair

4.2.1 Performing a leak-down test

4.2 General procedures

4.2.1 Performing a leak-down test

When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.


Equipment, etc.

Leak-down tester

Leak detection spray -

-


Performing a leak-down test

1

2

3

Action

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

Note

Remove the upper oil plug on the gear and replace it with the leak-down tester.

Regulators, which are included in the leak-down test, may be required.

Use caution, apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer.

Correct value:

0.2-0.25 bar (20-25 kPa)

CAUTION

The pressure must under no circumstance be higher than 0.25 bar (20-25 kPa). Also during the time when the pressure is raised.

4

5

6

7

8

Disconnect the compressed air supply.

Wait for approximately 8-10 minutes and make sure that no pressure loss occurs.

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

If any pressure drop occurred, then localize the leak

as described in step 7.

If no pressure drop occurred, then remove the leakdown tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detection spray. Bubbles indicate a leak.

When the leak has been localized, take the necessary measures to correct the leak.

178




4 Repair

4.2.2 Mounting instructions for bearings

4.2.2 Mounting instructions for bearings

General

This section describes how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.

1

2

3

Action

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

Note

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

Bearing rings, inner rings, and roller elements must not be subjected to direct impact. The roller elements must not be exposed to any stresses during the assembly work.

Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot.

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

1

Action

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

Note

Note

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

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

Greasing of bearings

Note

This instruction is not valid for solid oil bearings.





179

4 Repair

4.2.2 Mounting instructions for bearings

Continued

The bearings must be greased after assembly according to the following instructions:

• The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

• During operation, the bearing should be filled to 70-80% of the available volume.

• Ensure that grease is handled and stored properly to avoid contamination.

Grease the different types of bearings as following description:

• Grooved ball bearings must be filled with grease from both sides.

• Tapered roller bearings and axial needle bearings must be greased in the split condition.

180




4 Repair

4.2.3 Mounting instructions for seals

4.2.3 Mounting instructions for seals

General

This section describes how to mount different types of seals onto the robot.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below describes how to fit rotating seals.

CAUTION

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

• Keep the seal in its original wrappings or protect it well before actual mounting.

• The fitting of seals and gears must be carried out on clean workbenches.

• Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.

1

2

3

4

Action

Check the seal to ensure that:

• The seal is of the correct type (provided with cutting edge).

• There is no damage to the sealing edge (feel with a fingernail).

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

Note

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

Fill 2/3 of the space between the dust tongue and sealing lip with grease. The rubber coated external diameter must also be greased, unless otherwise specified.

Article number is specified in

Equipment on page 181 .

Mount the seal correctly with a mounting tool.

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

Make sure no grease left on the robot surface.





181

4 Repair

4.2.3 Mounting instructions for seals

Continued

Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.

1

2

3

4

Action

Check the flange surfaces. They must be even and free from pores.

It is easy to check flatness using a gauge on the fastened joint (without sealing compound).

If the flange surfaces are defective, the parts may not be used because leakage could occur.

Clean the surfaces properly in accordance with the recommendations of ABB.

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

Tighten the screws evenly when fastening the flange joint.

O-rings

The following procedure describes how to fit o-rings.

1

2

3

4

5

Action Note

Ensure that the correct o-ring size is used.

Check the o-ring for surface defects, burrs, shape accuracy, or deformation.

Check the o-ring grooves.

The grooves must be geometrically correct and should be free of pores and contamination.

Defective o-rings may not be used.

Lubricate the o-ring with grease.

Defective o-rings, including damaged or deformed o-rings, may not be used.

Tighten the screws evenly while assembling.

Make sure that no grease is left on the robot surface.

182




4 Repair

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

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

General

Follow the procedures in this section whenever breaking the paint of the robot during replacement of parts.


Equipment

Cleaning agent

Knife

Spare parts

Lint free cloth

Touch up paint Standard/Foundry

Plus, ABB Orange

3HAC037052-001

Removing

Note

Ethanol

1

Action

Cut the paint with a knife in the joint between the part that will be removed and the structure, to avoid that the paint cracks.

Description

2 Carefully grind the paint edge that is left on the structure to a smooth surface.

xx0900000121




183

4 Repair

4.2.5 The brake release buttons may be jammed after service work

4.2.5 The brake release buttons may be jammed after service work

Description

The brake release unit has push-buttons for the brake release of each axis motor.

When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting.

DANGER

If the power is turned on while a brake release button is jammed in depressed position, the affected motor brake is released. This may cause serious personal injuries and damage to the robot.

Elimination

1

2

3

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

4

Action

Make sure the power is turned off.

Remove the push-button guard, if necessary.

Verify that the push-buttons of the brake release unit are working by pressing them down, one by one.

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

If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes.

184




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 the lower end of the cable harness.

The procedure for replacing the upper end is detailed in the 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 SMB/BU unit





185

4 Repair


Continued

G

H

E

F

B

C

D

Top cover, connection box

Connection plate, base

Connector R1.SMB

Connector R1.MP

Metal clamps

Cable harness

Cable guide (cut away view)


Equipment, etc.

Cable harness

Standard toolkit

Spare part no.

See


.

Art. no.

-

Note

Other tools and procedures may be required.

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

Circuit diagram




See chapter


Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.

Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table.

1

Action

Decide which calibration routine to use for calibrating the robot.

• Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot.

• Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot.

Note

If the robot is to be calibrated with reference calibration:

Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot.

If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible.

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

Creating new values requires possibility to move the robot.

Read more about reference calibration for

Axis Calibration in

Reference calibration routine on page 320

.


Pendulum Calibration in Operating manual - Calibration Pendulum .





Removal

4 Repair


Continued

Action

If the robot is to be calibrated with fine calibration:

Remove all external cable packages

(DressPack) and tools from the robot.

Note

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

1

2

Action

Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.

Note

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

3

DANGER

Turn off all:





4 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 185 .





187

4 Repair


Continued

5

Action

Disconnect the earth cable.

Note

6

7

8 xx0600003028

• A: Earth (placed beneath the top cover)

• B: Top cover, connection box

Disconnect connectors R1.MP

and R1.SMB

on the connection plate, base .

Shown in the figure


1-2 on page 185 .

Disconnect all connectors at motors 1 R2.MP1, R2.FB1

and

2 R2.MP2, R2.FB2

.

Shown in the figure


1-2 on page 185 .

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

Shown in the figure


1-2 on page 185 .


188




Refitting

4 Repair


Continued

9

Action

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 update of the revolution counter is necessary!

Note

10

11

12 xx0600003026

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

• B: SMB/BU unit

• C: Battery unit

• D: Box

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

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

Shown in the figure


1-2 on page 185 .

Continue removal of the cable harness, axes 3-6.



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

1

2

Action Note

Push the cable harness axes 1-

2 carefully down through the cable guide in the center of the frame.

Shown in the figure


1-2 on page 185 .

Reconnect the connectors

R1.MP

and R1.SMB

at the connection plate, base .

Tightening torque for R1.SMB: 10 Nm.

Shown in the figure


1-2 on page 185 .





189

4 Repair


Continued

3

Action

Reconnect the earth cable.

Note

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

xx0600003028

• A: Earth (placed beneath the top cover)

• B: Top cover, connection box

5

6

7 xx0600003026

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

• B : SMB/BU unit

• C : Battery unit

• D : Box

Reconnect all connectors at motors 1 R2.MP1, R2,FB1 and

2 R2.MP2, R2.FB2

.

Shown in the figure


1-2 on page 185 .

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

Shown in the figure


1-2 on page 185 .

Refit the top cover, connection box .

Shown in the figure


1-2 on page 185 .


190




4 Repair


Continued

8

Action

Recalibrate the robot.

9

DANGER



Note

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

Axis Calibration is described in

Calibrating with Axis

Calibration method on page 319 .

General calibration information is included in section





191

4 Repair

4.3.2 Replacement of cable harness, upper end

4.3.2 Replacement of cable harness, upper end

Introduction

The cable harness 1-6 is undivided.

Replacing the cable harness is described in two steps:

• lower end (axes 1-2)

• upper end (axes 3-6)

This procedure details how to replace the upper end.

For description of how to replace the lower end, see


.

Location of cable harness

The cable harness for the axes 3 to 6 runs throughout the lower and upper arm as shown in the figure below: xx0600003078

E

F

G

A

B

C

D

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)





4 Repair


Continued


Equipment, etc.

Cable harness axes 1-6

Gasket

Gasket

Note

See


Motors axes 1-5

See


Motor axis 6. Recommended to be changed for Foundry Plus.

See


Retrofit set Foundry Plus, wrist

Retrofit set Foundry Plus, upper arm axis 4

See


See


Standard toolkit Content is defined in section


.


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


Circuit diagram See chapter


.




1

Action Note










Axis Calibration in


.










193

4 Repair


Continued

Removal

The procedure below details how to remove the cable harness.

1

2

Action


Note

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

3

DANGER

4

5

Turn off all:





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

1-2.



.

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

Note

Foundry Plus

Make sure not to lose the washers placed in the holes of the foundry gasket.

xx0600003024

• A : Cover, wrist unit xx1400002580


194




4 Repair


Continued

6

Action

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

Note

7 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

8 Remove the cable holder in the wrist unit by unscrewing 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: T xx0600003034

• A : Cable holder

• B : Attachment screws M6x16, 8.8

(2 pcs)

• C : Attachment screw M4x12, 8-

A2F (securing the carrier)


195


4 Repair


Continued

9

10

Action

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

Pull out the cabling R2.MP6

and R2.FB6

from motor axis 6 .

11 Disconnect all connectors at motor axis 6

R2.MP6

and R2.FB6

.

Note

Shown in the figure

Location of cable harness on page 192

Shown in the figure


12

13

Remove the cover of motor axes 3 and 4 by removing its attachment screws.

Disconnect all connectors at motor axes 3

R2.MP3, R2.FB3

and 4 R2.MP4, R2.FB.4

.

Shown in the figure


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

15 Foundry Plus

Remove the Foundry Plus arm house cover.

xx0600003083

• A : Metal clamp, lower arm (2 pcs)

• B : Metal clamp, gearbox axis 3

• C : Metal clamp, armhouse

16

17

Use caution and pull out the cable harness of the upper arm.

Tie the connectors into a bundle, to avoid damaging them during further removal.

xx1400002582


196




Refitting

4 Repair


Continued

The procedure below details how to refit the cable harness.

1

2

3

4

5

Action

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

Note


Replacement of cable harness, lower end (axes 1-2) on page 185 .

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

Arrange the cable harness as shown in the figure


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


We recommend changing the gasket on the cover for Foundry Plus robots.

Reconnect all connectors at motor axes 3

(R2.MP3, R2.FB3) and 4 (R2.MP4, R2.FB4) .

Refit covers motor axes 3 and 4. Make sure to turn the revolution indicator with the green side towards axis 4 center.

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 (M4x10) is located at the bottom of the cable holder, securing the carrier.

xx1500002404

7

8 xx0600003034

• A : Cable holder

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

• C . Attachment screws M4x10, quality 8-A2F (securing the carrier)

Reconnect the motor cables axis 6 R2.MP6

and R2.FB6

.

Shown in the figure


Refit cover motor, axis 6.




197


4 Repair


Continued

9

10

Action Note

Reconnect the motor cables axis 5 R2.MP5

and R2.FB5

.

Shown in the figure


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

(A) .

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

xx0600003032

• A : Cover

• B : Attachment screws M6x30, 8.8

(2 pcs)

• C : Cover motor, axis 5

• D : Attachment screws xx0600003030

• A : Cable harness

• B : Motor, axis 5

• C : Attachment screws M6x16, 8.8

(2 pcs)

• D : Metal clamp


198




4 Repair


Continued

12

Action

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

Note xx0600003083

• A : Metal clamp, lower arm (2 pcs)

• B : Metal clamp, gearbox axis 3

• C : Metal clamp, armhouse

13 Standard

Fit the wrist cover.

14 Foundry Plus

Make sure the wrist cover gasket and the small gasket fitted in the recess of the wrist cover are undamaged. Replace if damaged.

xx0600003024

• A : Cover, wrist unit xx1400002579





199

4 Repair


Continued

15

Action

Foundry Plus

Make sure the washers are fitted in the gasket holes.

Note

16

17

Foundry Plus

Fit the wrist cover, Foundry Plus.

Make sure the gasket stays undamaged after fitting. Replace if damaged.

Foundry Plus

Make sure the gasket on the adapter ring is undamaged. Replace if damaged.

xx1400002580

18 Foundry Plus

Fit the Foundry Plus cover on the adapter ring.

xx1400002581

19 Make sure the gasket on the adapter ring is undamaged. Replace if damaged.

xx1400002582


200




4 Repair


Continued

20

Action


21

DANGER


First test run may cause injury or damage on page 27

.

Note



Calibrating with Axis Calibration method on page 319 .


Calibration on page 305

.




201

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 axis-1 gearbox axis 1. This is shown in the figure below.

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


xx0600003035

F

G

D

E

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)


Equipment, etc.

Lifting accessory, robot

Art. no.

3HAC026597-001

Note

Instruction 3HAC026600-002 is enclosed!


202




4 Repair


Continued

Equipment, etc.

Guide pins M12 x 130

Roundsling 1,5 m

Roundslings

Hoisting block

Lifting chain

Isopropanol

Standard toolkit

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

-

-

-

-

-

Art. no.

3HAC022637-001

Note

Used to guide the complete arm system when lifting it.

Always use the guide pins in pairs!

In order to make the refitting easier, it is recommended to use two guide pins of different lengths.

Lifting capacity 1,000 kg

Used to adjust the length of the lifting chain.

Used together with the hoisting block.

Used for cleaning mounting surfaces.



.





1

Action




Note







Axis Calibration in


.









203


4 Repair


Continued

Removal, arm system

Use this procedure to lift and remove the complete arm system.

1

2

Action


Note

Run the robot to the position shown in the figure to the right.

Release the brakes if necessary, as detailed in section


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

xx0600003125


204




4 Repair


Continued

4

Action Note

Fit the lifting accessory 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 accessory!

Read the instructions before lifting!

Note

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

5

DANGER

Turn off all:





xx0600003101

• A : Lifting tool

• B : Roundsling

• C : Lifting chain

• D : Hoisting block

6

7

8

9

Drain the oil from gearbox axis

1.

Detailed in section

Changing oil, axis-1 gearbox on page 151

.

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

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

How to replace the cabling is detailed in


Remove the motor, axis 1.

Detailed in section

Replacement of motor, axis 1 on page 242

.




205


4 Repair


Continued

Action Note

10 Alternate method of lifting:

Fit the lifting accessory 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 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 accessory!

Follow the instructions before lifting!

Releasing the brakes is detailed in section


.

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!

11 Remove the mechanical stop pin from the frame.

xx0600003100


• B : Roundsling



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

A xx1200000668

A Mechanical stop pin


206




4 Repair


Continued

Action

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

Note

Shown in the figure

Location of arm system on page 202

.

xx0600003070

Parts:

• A: Serrated lock washer

• B: Gearbox axis 1

• C: Attachment screws M12x80

13 Fit two guide pins in two opposite screw holes.

Art. no. is specified in section


.

14

CAUTION

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

15 Lift the arm system carefully and secure it in a safe area.

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

Continue lifting even if the arm system turns out to be unbalanced despite earlier adjustments! The risk of damaging the interfaces is bigger if the load is lowered unbalanced!

Make sure all hooks and attachments stay in the correct position while lifting the arm system and that the lifting accessory does not wear against sharp edges.

Refitting, arm system

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

Action Note

1

DANGER

Turn off all:









207

4 Repair


Continued

2

Action Note

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

Also fit a hoisting block to the front.

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

Note

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



Make sure the lift is done completely level!

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


Releasing the brakes are detailed in section


xx0600003101


• B : Roundsling




208




4 Repair


Continued

3

Action Note

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.


See the lifting instructions .




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




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 to the right!

4

CAUTION

The complete arm system weighs 590 kg!

All lifting equipment used must be sized accordingly!

xx0600003100


• B : Roundsling




5

6

Lift the complete arm system and move it at very low speed, making sure it does not tip!

Make sure the lift is done completely level.

Adjust the length of the chains as detailed in enclosed instruction or with a hoisting block.

Clean the mounting surfaces with isopropanol.





209

4 Repair


Continued

7

Action Note

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

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

Dimension is specified in


.

Note

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

xx0600003095

The figure below shows the gearbox, axis

1.

A Attachment holes for guide pins,

M12 in gearbox axis 1.

B Hole for attachment screw.

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


210




4 Repair


Continued

9

Action Note

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

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

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

This is a complex task to be performed with utmost care in order to avoid injury or damage!

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 accessory 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.

10 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 202 .

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

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


before fitting.

11 Refit the axis-1 motor .

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

13 Refit the cabling in the base.

Detailed in section

Detailed in section

Performing a leakdown test on page 178

.


14 Refill the gearbox with lubricating oil.

Detailed in section


.




211


4 Repair


Continued

15

Action


16

DANGER



Note






212




4 Repair

4.4.1 Replacing the turning disk

4.4 Upper and lower arm

4.4.1 Replacing the turning disk

Location of turning disk

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

The figure shows the turning disk on an IRB 6620 Foundry Plus/IRB 6620LX.

xx0600003082

C

D

A

B

E

Turning disk

Wrist unit

Oil plug, draining

Oil plug, filling

Attachment screws, turning disk (6 pcs)


Equipment, etc.

Turning disk

Art. no.

For spare part no.

see:


Note

O-rings are not included!

O-ring

Wrist, type 1

O-ring

Wrist, type 2

Grease

Flange sealant

Standard toolkit

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

3HAB3772-65 (1pc)

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

3HAC034903-001

Used to lubricate the o-rings.

Loctite 574



.





213


4 Repair


Continued

Removing, turning disk

Use this procedure to remove the turning disk.

1

Action Note

Run the robot to a position where the oil plug, draining of axis 6 gearbox faces downwards.

Shown in the figure

Location of turning disk on page 213

.

2

DANGER

Turn off all:




3

4

5

6

7

Remove any equipment fitted to the turning disk.

Drain the axis 6 gearbox.

See section

•


Remove the attachment screws that secure the turning disk.

Remove the turning disk .

Foundry Plus:

Remove old flange sealant residues and other contamination from the contact surfaces.

Shown in the figure

Location of turning disk on page 213

.


214




4 Repair


Continued

Refitting, turning disk

Use this procedure to refit the turning disk.

1

Action Note

Lubricate the o-ring of the turning disk with grease and fit it to the turning disk.

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



.

2 Foundry Plus:

Apply Loctite 574 flange sealant on the contact surface.

xx0200000218

• A: Sealing surface, o-ring xx1400000995

3 Secure the turning disk with its attachment screws .

4

5

Perform a leak-down test of the gearbox axis

6.

Refill the axis 6 gearbox with oil.

6 pcs M14 x 25, 12.9 quality.




before fitting.


Performing a leak-down test on page 178

.

See section

•


6 Refit any equipment removed during disassembly to the turning disk.




215


4 Repair


Continued

Action

7

DANGER



Note

216




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

D

E

F

A

B

C

I

G

H

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

Spare part no.

See


.

Art. no.

Wrist unit, insulated See


.


See


.



Note


217


4 Repair


Continued

Equipment, etc.

Spare part no.


See


.

Art. no.

Roundsling

Grease

Standard toolkit -

-

3HAB 3537-1



Note

Used to lubricate o-rings.







1

Action




Note







Axis Calibration in


.






Removal

The procedure below details how to remove the wrist unit.

1

2

Action


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

Note





4 Repair


Continued

Action Note

3

DANGER

Turn off all:





4

5

Remove all equipment fitted to the wrist unit .

Shown in the figure in

Location of wrist unit on page 217

.

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

Shown in the figure


.

Note

Foundry Plus

Make sure not to lose the washers placed in the holes of the Foundry Plus gasket.

xx1400002580

6 Remove the cable harness, axes 5 and 6.

Detailed in section


.

7

CAUTION

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

8

9

10

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

Unscrew the eight attachment screws securing the wrist unit.

Shown in the figure


.

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

Note!

Do not damage the cylindrical pin in the process.

Refitting

1

Action

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

Note




219


4 Repair


Continued

2

3

4

5

6

Action

CAUTION

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

Put some grease on the surface of the fit.

Check the cylindrical pin.

Fit the wrist with its 8 attachment screws and washers.

Refit the cable harness, axes 5 and 6.

7

8

Standard

Fit the wrist cover.

Foundry Plus

Make sure the wrist cover gasket and the small gasket fitted in the recess of the wrist cover are undamaged. Replace if damaged.

Note

If the pin is damaged replace it.

M12x50 12.9 gleitmo (8 pcs)




Shown in the figure


.

9 Foundry Plus

Make sure the washers are fitted in the gasket holes. Refit the wrist cover, Foundry Plus.

xx1400002579


220

10 Recalibrate the robot.


xx1400002580

Pendulum Calibration is described in Operating manual - Calibration

Pendulum , enclosed with the calibration tools.


Calibrating with Axis Calibration method on page 319

.



.



4 Repair


Continued

11

Action

Refit any equipment previously removed from the wrist unit.

Note

12

DANGER






221

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

A

B

C

D

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.

Upper arm (Axes 3-4) See


.

Art. no.

O-ring

Lifting tool 3HAC026597-001

Note

Replace only if damaged.

Instruction 3HAC026600-

002 is enclosed.

Lifting chain

Roundsling

Guiding pins

Hoisting block

Grease

-

-

-

3HAB3537-1

Always use in pairs.






4 Repair


Continued

Equipment, etc.

Standard toolkit

Spare part no.

-

Art. no.

Note



.





1

Action




Note







Axis Calibration in


.






Removal



The procedure below details how to remove the upper arm.

1

Action


Note





223

4 Repair


Continued

Action Note

2

DANGER

Turn off all:





3

4

Drain the oil from gearbox axis 3.


Changing oil, axis-

3 gearbox on page 157 .

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

5

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!

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

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



7 Remove the cable harness, axes 3-6.

xx0600003102


• B : Roundsling





.


224




4 Repair


Continued

8

Action

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

Note

Refitting

9

10

11 xx0600003083

• A: Metal clamp, lower arm (2 pcs)

• B: Metal clamp, gearbox axis 3

• C: Metal clamp, armhouse

Remove motor, axis 3.

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

Note!

Do not forget to remove the four screws inside the hole in the lower arm.

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


Replacement of motor, axis 3 on page 253 .

Shown in the figure

Location of the upper arm on page 222 .

The procedure below details how to refit the upper arm.

1

Action

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

Lightly lubricate the o-ring with grease.

Note

2

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!





225

4 Repair


Continued

3

Action Note

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 which is used to adjust the balance of the upper arm in order to lift it completely level.

Art. number is specified in


.

6

7

4

5

8

Fit the guiding pins in gearbox axis 3.

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

Note ! Do not forget the four screws inside the hole in the upper arm.

Shown in the figure

Location of the upper arm on page 222 .

Remove the guiding pins.

Refit motor, axis 3.



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

xx0600003102


• B : Roundsling



9

10

Perform a leak-down test of the axis-3 gearbox.

Refit the cable harness, axes 3-6.

xx0600003083

• A: Metal clamp, lower arm (2 pcs)

• B: Metal clamp, gearbox axis 3

• C: Metal clamp, armhouse

Detailed in section


.

Detailed in section


.





4 Repair


Continued

11

12

Action

Fill gearbox, axis 3 with oil.


13

DANGER



.

Note

Detailed in section


.









227

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 figure below.

xx0600003058

C

D

A

B

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



228




4 Repair


Continued


Equipment, etc.

Lower arm

Grease

Lifting tool

Lifting chain

Hoisting block

Roundslings

Guiding pins

Standard toolkit


Spare part no.

See


Art no.

3HAB3537-1

3HAC026597-001

Note



002 is enclosed.

-

-

-

-








1

Action




Note







Axis Calibration in


.









229


4 Repair


Continued

Removal

The procedure below details how to remove the lower arm.

1

2

Action


Move the robot to the position shown in the figure to the right.

Note xx0600003125

3

DANGER

Turn off all:





4

5

6

7

Remove the cable harness axes 3-6.



.

Let the cable harness hang loose, without it getting damaged in the proceeded removal procedure.

Remove the upper arm.


Replacement of the upper arm on page 222

.

Secure the lower arm with a roundsling in an overhead crane.





4 Repair


Continued

Action Note

8

CAUTION

The lower arm weighs 75 kg

(gearboxes axes 2-3 excluded)!

9

10

Remove the attachment screws and washers securing the lower arm to gearbox axis

2.

Shown in the figure

Location of lower arm on page 228 .

Remove the lower arm.

Refitting

The procedure below details how to refit the lower arm.

1

Action

Secure the lower arm with a roundsling and lift it to its mounting position.

Note

2

CAUTION

The lower arm weighs 75 kg (gearboxes axes

2-3 excluded)!

3

4

7

8

5

6

9

10

11



Fit guiding pins in two of the holes in gearbox axis 2.

Lift the lower arm on to the guiding pins.

Refit the attachment screws and washers securing the lower arm to gearbox axis 2.

Shown in the figure

Location of lower arm on page 228 .

M16x50, quality 12.9 gleitmo (16 pcs).


Remove the guiding pins.

Secure the upper arm with a roundsling and lift it to its mounting position.

Refit the upper arm.


Replacement of the upper arm on page 222

.

Refit the cable harness axes 3-6.




.

Pendulum Calibration is described in

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



.



.




231


4 Repair


Continued

Action

12

DANGER



Note

232




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 = brake release 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.

H

G

F

I A

B

C

D1

D2

E xx0600003052

F

G

E

F

H

I

J

A

B

C

D1

D2

Attachment screws (4 pcs)

SMB/BU unit

Velcro strap



SMB/BU box

Serial measurement unit (SMB), DSQC 633A

Serial measurement unit (SMB), RMU 101

Brake release unit (BU), DSQC 1050

Push button guard

Cover, push button guard

Gasket (Foundry Plus)





233

4 Repair


Continued


Note

There are different variants of SMB units and batteries. The variant with the

3-pole battery contact has longer lifetime for the battery.

It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact!

Equipment, etc.

Serial measurement unit (SMB)

Spare part no.

Standard toolkit

Circuit diagram

-

Art. no.


Note


Special tools on page 347 .

See chapter


.

Removal, SMB unit

1

2

The procedure below details how to remove the SMB unit.

Action

Move the robot to the calibration position.

Note

DANGER

Turn off all:





3

ELECTROSTATIC DISCHARGE (ESD)

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


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 233

.

CAUTION




234




4 Repair


Continued

5

Action

Carefully disconnect the connectors from the

SMB unit.

Note

Connectors R1.SMB1-3, R1.SMB4-6 and R2.SMB

6 Disconnect the battery cable by pressing down the upper lip of the R1.G connector to release the lock while pulling the connector upwards.

xx0600003054

7 Unscrew the hexagon nuts securing the SMB unit just enough to pull the SMB unit out.

xx1700000993

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


235

4 Repair


Continued

Refitting, SMB unit

The procedure below details how to refit the SMB unit.

1

Action

Push the SMB unit into its tracks and secure it with its hexagon nuts.

Note

2 Reconnect the connectors to the SMB unit.

If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm.

xx0600003053

• A : Hexagon nut, M5

• B : Tooth lock washer, 6.4 fzb

• C : Hexagon screw, M5x12 quality 8.8

xx0600003054

3

4

5

Reconnect the battery cable.

Make sure the lock on the battery cable connector R1.G snaps into place during refitting.

Connector R1.G

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

Shown in the figure

Location of SMB unit on page 233

.

Update the revolution counters!

Detailed in section

Updating revolution counters on page 313 .





Action

6

DANGER



Note

4 Repair


Continued




237

4 Repair

4.5.2 Replacing the brake release board

4.5.2 Replacing the brake release board

Location of brake release board

The SMB/BU unit (SMB = serial measurement board, BU = brake release 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.

H

G

F

I A

B

C

D1

D2

E xx0600003052

E

F

G

A

B

C

D

I

H

J


SMB/BU unit

Velcro strap

Battery pack

SMB/BU box

Serial measurement unit (SMB), DSQC633

Brake release unit (BU), DSQC1050

Push button guard

Cover, push button guard

Gasket (Foundry Plus)


Equipment, etc.

Brake release board including harness and bracket

Standard toolkit


-


3HAC066539-

001

DSQC1050



.






4 Repair


Continued

Removing, brake release board

Use this procedure to remove the brake release board.

Action Note

1

DANGER

Turn off all:





2

ELECTROSTATIC DISCHARGE

(ESD)



3

4

5

6

Remove the cover for the push button guard.

Remove the push button guard from the SMB cover.

Shown in the figure

Location of brake release board on page 238

.

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

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

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!

CAUTION



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

X9

X8

X10 xx1700000978

Location of the brake release unit is shown in the figure


.




239


4 Repair


Continued

8

Action

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

Note

Refitting, brake release board

Use this procedure to refit the brake release board.

Action Note

1

ELECTROSTATIC DISCHARGE (ESD)



2 Connect the connectors X8, X9 and X10 to the brake release board.

Be careful not to damage the sockets or pins.

Make sure the connector and its locking arms are snapped down properly.

X9

X8

X10 xx1700000978

3

4

5

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

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

Maximum tightening torque: 5 Nm.

Shown in the figure


.



.

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

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

WARNING

Screened cables must not get in contact with the brake release board after installation.

Eliminate all risks of contact between screened cables and the brake release board.

6

WARNING

Before continuing any service work, follow the safety procedure in

The brake release buttons may be jammed after service work on page 184 .

7

8

Refit the push button guard to the SMB cover.

Shown in the figure


.

Refit the cover, push button guard .





4 Repair


Continued

Action Note

9 Press the push buttons 1 to 6, one at a time, to make sure that the buttons are moving freely and do not stay in a locked position.

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

Detailed in the Calibration chapter section


.

11

DANGER






241

4 Repair

4.6.1 Replacement of motor, axis 1

4.6 Motors

4.6.1 Replacement of motor, axis 1

Note

This procedure requires calibration of the robot.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.

Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant.

Location of motor

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

xx0600003037

C

D

A

B

Motor, axis 1

Motor attachment screws and washers

Cable gland

Cover


242




4 Repair


Continued


Equipment, etc.

Spare part no.

Motor including pinion See


.

Art. no.

O-ring

Mobilux EP 2

Grease

Removal tool, motor

M12x

Lifting tool, motor ax

1, 4, 5

Power supply

Standard toolkit

Calibration Pendulum toolkit

Calibration tool box,

Axis Calibration



Circuit diagram

-

21522012-430

-

3HAB3537-1

Note

Includes

• motor

• pinion

• o-ring 21522012-

430.

Must be replaced when reassemling the motor.

Used to lubricate the motor clutch.

Used to lubricate the oring.

Always use the removal tools in pairs!

3HAC14973-1

3HAC14459-1

-

-

3HAC15716-1

24 VDC, max. 1,5 A

For releasing the brakes.



.

Complete kit that also includes operating manual.

Required if Calibration

Pendulum is the valid calibration method for the robot.

3HAC055412-001 Delivered as a set of calibration tools.

Required if Axis Calibration is the valid calibration method for the robot.


See chapter


.





243

4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, motor axis 1

The procedure below details how to remove motor, axis 1.

Note

1

Action


2

DANGER

Turn off all:





3 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 242 .


244




4 Repair


Continued

4

Action

Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

Note

Note

Make sure the gasket is not damaged!

5

6

7

8 xx0200000199

• A: Cable gland cover

Disconnect all connectors beneath the motor cover.

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



.

In order to release the brakes, connect the 24 VDC power supply.

Connect to connector R2.MP1

• +: pin 2

• -: pin 5

Remove the motor by unscrewing its four attachment screws and plain washers.

Shown in the figure


9

CAUTION

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

10

11

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

Remove the motor by gently lifting it straight up.

Refitting, motor axis 1

The procedure below details how to refit motor, axis 1.

Action Note

1

DANGER

2

Turn off all:





Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the oring with grease.

Art no. is specified in


.

3

CAUTION





245


4 Repair


Continued

7

8

4

5

6

9

10

11

12

13

Action Note

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



.

In order to release the brake, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5

Fit the motor, making sure the motor pinion is properly mated to gearbox of axis 1.

Make sure the motor is turned the correct way, that is connection of motorcable as shown in the figure


Make sure the motor pinion does not get damaged!

Fit the clutch on the pinion on the motor.

Secure the motor with its four attachment screws and plain washers.

M10 x 40, tightening torque: 50

Nm.

Disconnect the brake release voltage.

Reconnect all connectors beneath the motor cover.

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

Make sure the cover is tightly sealed!

Refit the motor cover with its four attachment screws.

Recalibrate the robot!








.

14

DANGER



246




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.

xx0600003040

A

B

C

Motor, axis 2

Motor attachment holes (4 pcs)

Cable gland


Equipment, etc.

Motor including pinion

Spare part no.

See


Art. no.

O-ring

Grease

Removal tool, motor

M12x


21522012-430

Lifting tool, motor ax

2,3

Extension bar, 300 mm for bits 1/2"

3HAB3537-1

3HAC14973-1

3HAC15521-2

3HAC026061-001

3HAC12342-1

Note

Includes

• motor

• pinion

• o-ring 2152 2012-430

Must be replaced when reassembling motor!

For lubricating the o-ring.


For guiding the motor.

Guides are to be used in pairs!




247


4 Repair


Continued

Equipment, etc.

Power supply

Rotation tool

Standard toolkit



Axis Calibration

Spare part no.

-

-

Art. no.

3HAC17105-1

3HAC15716-1

3HAC055412-001

Note

24 VDC, 1.5 A


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




Required if Calibration Pendulum is the valid calibration method for the robot.

Delivered as a set of calibration tools.






.




1

Action




Note


248




4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, motor

The procedure below details how to remove the motor, axis 2.

1

2

Action Note


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


3

DANGER

Turn off all:





4

5

Drain the oil from gearbox, axis 2.



Remove the cover on top of the motor by unscrewing its four attachment screws.




249


4 Repair


Continued

6

7

8

Action

DANGER

Note


Shown in the figure




Use the lock screw to lock the lower arm, as detailed above!

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!

9 In order to release the brake, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5

10 Remove the motor by unscrewing its four attachment screws and plain washers.

11 Fit the two guide pins in two of the motor attachment holes.



Shown in the figure


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


page 247 .

Shown in the figure

Required equipment on

Location of motor on page 247


.

13 Remove the removal tools and fit the lifting tool, motor axis 2, 3, 4 to the motor.



14

CAUTION


15 Lift the motor to get the pinion away from the gear.


16 Remove the motor by gently lifting it straight out and place it on a secure surface. Disconnect the brake release voltage.


250




4 Repair


Continued

Refitting, motor

The procedure below details how to refit the motor axis 2.

Action Note

1

DANGER

Turn off all:





2

3

4

5

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.



.

In order to release the brake, remove the cover on top of the motor and connect the 24

VDC power supply.


• +: pin 2

• -: pin 5

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



.

Fit the two guide pins in the two lower motor attachment holes.



.

Shown in the figure


.

6

CAUTION


7

8

Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

Make sure that the motor is turned the right direction, that is the cables facing as shown in the figure


.

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





251

4 Repair


Continued

9

Action Note

Use the rotation tool in order to rotate the motor pinion when mating it to the gear (see the figure to the right). Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox axis 2 and that it does not get damaged.



.

252

10

11

12

13

14

15

16

17

18 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in the figure above.

• A: Rotation tool

Remove the guide pins.

Secure the motor with four attachment screws and plain washers.

M10 x 40, tightening torque: 50 Nm.



before fitting.



Connect in accordance with markings on connectors.


Shown in the figure


.

Refit the cover on top of the motor with its four attachment screws.

Perform a leak down test.


Refill the gearbox with oil.


Detailed in


.









19

DANGER



.




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


Equipment, etc.

Motor, axis 3

Spare part no.

See


.

Art. no.

O-ring

Grease

Bolts M16x60

(for mechanical stop axis 3)

Guide pins M10 x

100

Guide pins M10 x

150

Rotation tool

21522012-430



3HAB3537-1

3HAB3409-86

Note

Includes:

• motor

• pinion

• o-ring 21522012-430



3HAC15521-1

3HAC15521-2

3HAC17105-1



Used to rotate the motor pinion when mating it to the gear when brakes are released with

24 VDC power supply.


253


4 Repair


Continued

Equipment, etc.

Power supply

Spare part no.

Standard toolkit


Calibration tool box, Axis Calibration

-

-

Art. no.

Note

24 VDC, max. 1.5 A




3HAC15716-1

3HAC055412-001







Circuit diagram 3HAC025090-001 See chapter


.




1

Action




Note







Axis Calibration in


.










4 Repair


Continued

Removal, motor


1

2

Action


Note

Move the robot to the position shown in the figure.

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

xx0600003041

3

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.







255

4 Repair


Continued

Action Note

5

DANGER

Turn off all:





6

7

8

Remove any equipment hindering access to motor axis 3.


Remove the cable gland cover at the cable exit by unscrewing its two securing screws.

Shown in the figure



9 Disconnect all connectors beneath the motor cover.

10 Unscrew the motors four attachment screws and plain washers .

Shown in the figure


11 Fit the two guide pins in two of the motor attachment screw holes.



12 Press the motor out of position by fitting removal tool, motor to the remaining motor attachment screw holes.




13 Apply the lifting tool, motor axis 2

,3, 4 to the motor.



14

CAUTION


15 Lift the motor to get the pinion away from the gear.

16 Remove the motor by gently lifting it straight out and disconnect the brake release voltage.

Make sure the motor pinion is not damaged!


256




4 Repair


Continued



Action Note

1

DANGER

Turn off all:





2

3

4

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate it with grease .



.

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



.

Fit the two guide pins in the two lower motor attachment holes.



.

Shown in the figure


5

CAUTION


6

7

8

Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

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



• +: pin 2

• -: pin 5





257

4 Repair


Continued

9

Action Note

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

Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 3.



.


Make sure the motor is turned the right direction, that is the cables facing forwards.

10

11

12

13

14 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

• A: Rotation tool.



4 pcs: M10 x 40, tightening torque:

50 Nm.



Connect in accordance with markings on connectors.



Shown in the figure


.

15

16

17

18

19


Remove the equipment used to unload the upper arm.


Perform a leak-down test.



.





.





.



.





4 Repair


Continued

Action

20

DANGER



Note




259

4 Repair




The motor axis 4 is located on the left-hand side of the upper arm as shown in the figure below.

xx0600003050

A

B

C

Cable gland cover, motor axis 4

Motor, axis 4



Equipment, etc.


O-ring

Grease

Loctite 574, Flange sealant

Guide pins M8 x 100

Guide pins M8 x 150

Rotation tool

Power supply

Standard toolkit

-

-

Art. no.

Note

See spare part number in


.

Includes:

• motor

• pinion

• o-ring 21522012-430

21522012-430

3HAB3537-1

12340011-116


Used to lubricate the o-ring.

Option Foundry Plus

3HAC15520-1

3HAC15520-2

3HAC17105-1



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

24 VDC, max. 1,5 A




.





4 Repair


Continued

Equipment, etc.


Art. no.

3HAC15716-1


3HAC055412-001

Note







Circuit diagram 3HAC024090-001 See chapter


.




1

Action Note










Axis Calibration in


.






Removal, motor axis 4


1

Action


Note




261


4 Repair


Continued

2

Action Note

Move the robot to a position where the upper arm is pointed straight up.

This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

Any other position of the upper arm requires a draining of oil from the gearbox for axis 4.

Draining of oil is described in section

Draining, oil on page 160

.

3

DANGER

Turn off all:





4

5

6

7

8

Remove the cable gland cover at the cable exit of the motor by unscrewing its two attachment screws.

Shown in the figure


.




In order to release the brake, connect the



• +: pin 2

• -: pin 5

Unscrew the motors four attachment screws and plain washers.

Shown in the figure


.

9 Fit the two guide pins in two of the motor attachment screw holes.

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




11 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

12 Remove the motor by gently lifting it straight out.


Refitting, motor axis 4


Action Note

1

DANGER

Turn off all:









4 Repair


Continued

2

3

4

5

6

Action Note




.

In order to release the brakes, connect the


Connect to connector R2.MP4:

• +: pin 2

• -: pin 5

Fit the two guide pins in two of the motor attachment holes.



.

Shown in the figure


Fit the motor with guidance of the pins, making sure the motor pinion is properly mated to the gear of gearbox 4.


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.

7

8

9

10

11

12 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

• A: Rotation tool.





4 pcs: M8 x 25, tightening torque: 24 Nm.




Shown in the figure


13

14

Perform a leak-down test if the gearbox has been drained.



.

Refill the gearbox with oil if drained.




263


4 Repair


Continued

15

Action


16

DANGER



.

Note






.

264




4 Repair

4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX

4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX


The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below.

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


xx0600003049

C

D

E

A

B

Cable harness

Motor, axis 5


Metal clamp

Cover, cable gland


Equipment, etc.

Motor


For spare part number, see


.




.

O-ring 21522012-430

Grease


Art. no.



.

Note

3HAB3537-1

12340011-116



Option Foundry Plus




265


4 Repair


Continued

Equipment, etc.

Art. no.

Removal tool, motor M10x 3HAC14972-1

Extension bar 300 mm for bits 1/2"

3HAC12342-1

Guide pins M8 x 100

Guide pins M8 x 150

Power supply

3HAC15520-1

-

3HAC15520-2

Standard toolkit


Circuit diagram -

-

Note




24 VDC, 1.5 A




.


See chapter





1

Action




Note







Axis Calibration in


.







266




4 Repair


Continued

Removal, motor, axis 5


1

2

Action


Note

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.

3

DANGER

Turn off all:





4 Remove the cover on the wrist unit by removing its attachment screws.

Note

Make sure not to lose the washers placed in the holes of the foundry gasket.

xx1400002580

5

6

7

8

9

10

11

12

Remove the metal clamp securing the cable harness.

Shown in the figure in section



Shown in the figure in section



Disconnect all connectors beneath the motor cover and remove the cable of the axis-5 motor.

Pull the cable harness out of the upper arm a little, far enough to make room for removal of the motor.

Shown in the figure in the section



Connect to:

- connector R2.MP5 (in the motor):

• + : pin 2

• -: pin 5


Fit the two guide pins in two of the motor attachment screw holes.






267


4 Repair


Continued

13

14

15

Action Note

If required, press the motor out of position by fitting removal tool, motor, M10 to the motor attachment screw holes.



Always use the removal tools in pairs and diagonally!

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.


Remove the motor by gently lifting it straight out.

Keep track of the shims between the motor flange and the wrist housing.

Refitting, motor, axis 5


Action Note

1

DANGER

Turn off all:





2

3

4

5

6

7

8

9

10

11

12




In order to release the brake, connect the 24

VDC power supply.

Connect to:

- connector R2.MP5 (in the motor):

• + : pin 2

• -: pin 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.


Refit the cable of the axis-5 motor and reconnect all connectors beneath the motor cover.




Refit the metal clamp securing the cable harness.

Shown in the figure in the section


.

Perform a leak-down test.



.

13 Standard

Refit the cover of the wrist unit with its attachment screws.





4 Repair


Continued

14

Action

Foundry Plus

Make sure that the gasket is undamaged. Also the small gasket fitted in the cover recess.

Replace if damaged.

Note

15 Foundry Plus

Make sure the washers are fitted in the gasket holes. Refit the cover, wrist unit Foundry Plus.

xx1400002579 xx1400002580

16

17

Refill the gear with oil.

Re-calibrate the robot.

18

DANGER





.










4 Repair




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)

Spare part no.



.

Art. no.


(insulated)



.

O-ring 21522012-430

Gasket

Gasket, cover

3HAC048560-001

3HAC033489-001


270


Note

Includes:

• motor

• pinion

• o-ring 21522012-430

Includes:

• motor

• pinion

• o-ring 21522012-430


Must be replaced when replacing motor

Must be replaced when opening cover.



4 Repair


Continued

Equipment, etc.

Removal tool, motor

M10x

Extension bar 300 mm for bits 1/2"

Guide pins M8 x 100

Guide pins M8 x 150

Power supply

Spare part no.

Grease


Standard toolkit



Axis Calibration

Art. no.

3HAC14972-1

Note


3HAC12342-1

-

3HAC15520-1

3HAC15520-2

3HAB3537-1

12340011-116



24 VDC, 1.5 A



Option Foundry Plus

-

3HAC15716-1

3HAC055412-

001



.













1

Action




Note





271

4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, motor


Note

Robots with protection type Foundry Plus or Foundry Prime require special repair routines to maintain the tightness level, in addition to the procedure below, described in

Replacement of the motor axis 6 (Foundry Plus) on page 275 .

1

2

Action


Move the robot to a position where the motor in axis 6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

Note

3

DANGER

Turn off all:





4

5

6

Remove the rear motor cover by unscrewing the five attachment screws.

Disconnect all connectors beneath the cover.



• +: pin 2

• -: pin 5


272




4 Repair


Continued

7

Action


Note

8 xx0600003038

• A: Tilthouse

• B: Motor, axis 6

• C: Attachment screws (4 pcs)

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



.


9 Lift the motor carefully to get the pinion away from the gear and disconnect the brake release voltage.


10 Remove the motor by gently lifting it straight out.



Note

Robots with protection type Foundry Plus or Foundry Prime require special repair routines to maintain the tightness level, in addition to the procedure below, described in

Replacement of the motor axis 6 (Foundry Plus) on page 275 .

1

2



Action


In order to release the brake, connect the 24

VDC power supply.

Note




• +: pin 2

• -: pin 5


273


4 Repair


Continued

3

4

Action Note




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!

5

6

7

8

9

10 xx0600003038

• A: Tilthouse

• B: Motor, axis 6

• C: Attachment screws


Secure the motor with its four attachment screws and plain washers.

4 pcs: M8 x 25, tightening torque: 24

Nm.



Refit the cover on top of the motor with its five attachment screws.







.







4 Repair


Continued

Action

11

DANGER



Note

Replacement of the motor axis 6 (Foundry Plus)

Robots with protection type Foundry Plus require special repair routines to maintain the tightness level.

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

Action Note

1

DANGER

Turn off all:





2 Remove the rear motor cover by unscrewing the five attachment screws.

3



Continue to remove the motor unit, according to step 6 and forwards in

Removal, motor on page 272

.

xx1500002524

• A: Motor unit

• B: Connection box

• C: Attachment screw (5 pcs)

• D: Rear motor cover

• E: Gasket


275


4 Repair


Continued

Action

4

Note

Keep the old rear motor cover with the air nipple.

5 Remove the protection strip on the gasket and mount it on the motor .

Note

6

7

Apply Mercasol 3106 on the motor end cover .


xx1500002425

• A: Attachment screw (4pcs)

Mercasol 3106

• B: Motor unit

• C: O-ring

• D: Sikaflex in screw recesses

• E: Tilt house

• F: Washer

• G: Rear motor cover

• H: Sealing

• J: Loctite 574

276

8

9

Apply grease on the o-ring on the motor .

Continue to refit the new motor according to section,

Refitting, motor on page 273

.

xx1400000992




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

F

G

D

E

A

B

C

Gearbox, axis 1 RV 320C-191.35

Attachment screw, M12x80 quality 12.9 gleitmo (16 pcs)

Attachment screw, M16x60 quality 12.9 gleitmo (12 pcs)

Base

Frame

Protection pipe axis 1

O-ring


Equipment, etc.

Gearbox, axis 1

Spare part no.

See


.

Art. no.

O-ring

O-ring (3 pcs)



3HAB3772-93

3HAB3772-97

Note

Includes:

• gearbox

• o-ring

Replace only when damaged.

380.6x3.53

23x3.6


277


4 Repair

4.7.1 Replacement gearbox axis 1

Continued

Equipment, etc.

Support, base and gear axis 1

Guide pins (M16x300)

Spare part no.


Lifting tool

Lifting tool

Lifting eye (2 pcs)

Grease

Standard tools

Art. no.

3HAC15535-1

Note

Consists of 4 pcs.

3HAC13120-5

3HAC13120-4

Always use guiding pins in pairs.

Always use guiding pins in pairs

3HAC026597-001

3HAC15556-1


002 is enclosed.

Used to lift gearbox axis 1 and frame.

3HAC025333-005 Used together with lifting tool 3HAC15556-1.

-

3HAB3537-1 For lubricating o-rings.








1

Action




Note







Axis Calibration in


.










Removal

4 Repair


Continued

The procedure below details how to remove the gearbox axis 1.

1

Action


Note

2

DANGER

3

4

5

Turn off all:





Remove motor, axis 1.

Detailed in section


Remove the cable harness, axes 1-2.

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


Run an overhead crane to a position above the robot.

6

CAUTION



7

8

9

10

Lift the robot (without the base) and put it safely on its side on the floor.

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 87 .

Fit two lifting eyes on each side of the gearbox and secure it with a roundsling.



Attach the lifting tool to the gearbox.



11

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!

12 Lift the robot base with gearbox axis 1, to allow fitting the support, base and gear axis

1 on each side of the base.







279

4 Repair


Continued

13

14

Action

Fit the support, base and gear axis 1.

Make sure the base remains in a stable position before performing any work underneath the base!

Unscrew the 12 attachment screws and washers securing the gearbox to the base.

Note

Refitting

15

CAUTION

The gearbox weighs 108 kg! All lifting equipment used must be sized accordingly!

xx0600003069

• A: Gearbox, axis 1

• B: Attachment screw, M16x60

16 Remove the gearbox.

The procedure below details how to remove the gearbox axis 1.

1

Action

If the base not already is resting on the support base and gear, axis 1 , this should be done first.

Note

Mounting of the support base and gear, axis 1 is detailed in section

Removal on page 279

.


280




4 Repair


Continued

2

Action Note

Make sure the o-ring is fitted to the gearbox as shown in the figure to the right.




3

4

5

6 xx0600003126

• A : O-ring (Gearbox shown from the side)

Use some grease to attach them.

Fit the three o-rings (23x3.6).

Refit the protection pipe axis 1 in the center of gearbox 1 with its attachment screws.

Shown in the figure

Location of gearbox axis 1 on page 277 .

Fit two lifting eyes on each side of the gearbox and secure it with a roundsling.



Fit two guide pins in two of the attachment holes, parallel to each other.

7

CAUTION


8 Lift the gearbox on to the guide pins and lower it carefully to its mounting position.





281

4 Repair


Continued

9

Action Note

Refit the gearbox to the base with its attachment screws and washers.

Shown in the figure


M16x60 quality 12.9 (12 pcs)


10

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!

xx0600003069

• A: Gearbox, axis 1

• B: Attachment screw, M16x60

11

12

Lift the robot base and gearbox 1 to allow removing the support, base and gear.

Secure the base to the mounting site.

Detailed in section

Orienting and securing the robot on page 87 .

13

CAUTION




282




4 Repair


Continued

14

Action Note

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




How to adjust the lift is described in the enclosed instruction to the lifting tool.

Read the instructions before lifting!

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

xx0600003101


• B : Roundsling

• C : Lifting sling






283

4 Repair


Continued

15

Action Note

Alternate method of lifting:

Fit the lifting tool 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.





How to adjust the lift is described in the enclosed instruction to the lifting tool.

Read the instructions before lifting!



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!

16 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


M12x80 quality 12.9 (16 pcs)



284 xx0600003070

• A: Serrated lock washer

• B: Gearbox, axis 1

• C: Attachment screw, M12x80




4 Repair


Continued

17

18

19

20

Action

Refit the cable harness, axes 1-2.

Refit motor, axis 1.

Fill oil in gearbox axis 1.


21

DANGER



Note

Detailed in section


Detailed in section


Detailed in section


.





.






285

4 Repair


4.7.2 Replacement gearbox axis 2


The gearbox axis 2 is located in the lower arm rotational center.

xx0600003056

C

D

A

B



Motor, axis 2

Gearbox, axis 2


Equipment, etc

Gearbox, axis 2

Spare part no.

See Spare parts

Art. no.

Note

Includes:

• gearbox

• o-ring

O-ring (339.3x5.7)

Grease

Lifting tool

3HAB3772-91

Lifting tool

Roundsling



Crank

Standard toolkit -

3HAB3537-1

3HAC026597-001

For lubricating o-rings.

Instruction

3HAC026600-002 is enclosed.

For lifting gearbox

-

3HAC025214-001

3HAC13056-4

3HAC13056-3

3HAC020999-001



Used to turn the gear in correct position.



.


286




4 Repair


Continued

Art. no.

Note





1

Action Note










Axis Calibration in


.






Removal

Equipment, etc



Spare part no.

The procedure below details how to remove gearbox axis 2.

1

Action


Note





287

4 Repair


Continued

2

Action

Jog the robot to the position shown in the figure to the right.

Note xx0600003125

3

CAUTION

The upper and lower arms (incl.

gearboxes axes 2 and 3) weighs

455 kg. All lifting equipment used must be sized accordingly!

4 Fit the lifting tool on the upper arm and secure the robot in an overhead crane.



.

5 xx0600003099


• B : Roundsling










4 Repair


Continued

Action Note

6

DANGER

Turn off all:





7

8

9

10

11

Remove the cable harness, axes

1-3.



Let the removed part of the cable harness hang loose and take care not to damage it during the removal process.

Remove the attachment screws

M16x50 (16 pcs) that secure the lower arm to gearbox axis 2.

Remove the upper and lower arms and put them down on the floor.

Shown in the figure

Location of gearbox axis 2 on page 286

.

Remove motor axis 2.


Replacement of motor axis

2 on page 247 .

12

13

Remove two attachment screws

(M12x60) parallel to each other.

Fit two guide pins in the holes, parallel to each other.

14

CAUTION






289

4 Repair


Continued

15

Action Note

Fit the lifting tool for lifting the gearbox in the uppermost hole and secure it with a roundsling.



.

Refitting

16

17

18 xx0900000114

The figure shows IRB6640.

Remove the attachment screws

M12x60 (24 pcs) securing the gearbox to the frame.

Remove the gearbox and put it in a place where it will not/cannot be damaged.

Shown in the figure


.

Wipe away residual oil and paint.

The procedure below details how to refit gearbox axis 2.

1

Action

Make sure the o-ring is fitted to the gearbox. Lightly lubricate it with grease.

Note xx0600003128

• A : O-ring 3HAB3772-91


290




4 Repair


Continued

Action Note

2

CAUTION


3 Fit the lifting tool for lifting the gearbox in the uppermost hole of the gearbox and secure it with a roundsling.



4

5

6 xx0900000114

The figure shows IRB6640.


Lift the gearbox on to the guide pins and push it in mounting position.

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!





291

4 Repair


Continued

8

Action Note

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

10

11 xx0600003099


• B : Roundsling



Use a crank in the gearbox in order to find the holes for the attachment screws.

Refit the lower arm to the gearbox axis 2 with its attachment screws.

M16x50 (16 pcs)


Refit motor axis 2.


Replacement of motor axis 2 on page 247 .

12

13

14

Refit the cable harness, axes

1-3.



Fill the gearbox axis 2 with oil.






Calibrating with Axis

Calibration method on page 319 .



.


292




Action

15

DANGER



.

Note

4 Repair


Continued




293

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

C

D

A

B

E

Motor, axis 3

Gearbox, axis 3

Attachment screws, M12x50 quality 12.9 gleitmo (20 pcs)

Attachment screws, M16x50 quality 12.9 gleitmo (16 pcs)

Hole in lower arm


Equipment, etc.

Gearbox, axis 3

O-ring

Grease

Lifting tool

Lifting tool

Standard toolkit

Spare part no.

See


Art. no.

Note

Includes:

• gearbox

• o-ring

Replace only if damaged.

3HAB3772-92

3HAB3537-1

3HAC026597-001

-

3HAC025214-001

Used to lubricate the o-ring.

Instructions 3HAC 026600-002 is enclosed.

For lifting gearbox.



.


294




4 Repair


Continued

Equipment, etc.



Spare part no.

Art. no.

Note





1

Action Note










Axis Calibration in


.






Removal

The procedure below details how to remove gearbox axis 3.

1

Action


Note





295

4 Repair


Continued

2

Action

Move the robot to the position shown in the figure to the right.

Note xx0600003125

3

DANGER

Turn off all:





4

5

6


Remove the upper arm.




Replacement of the upper arm on page 222 .

While the upper arm is resting on its side on the floor, fit the lifting tool in the uppermost hole of the gearbox.



7

CAUTION


8

9

Secure the gearbox with a roundsling in an overhead crane.

Remove the attachment screws securing the gearbox to the upper arm.

10 Remove the gearbox and put it in a safe place.

Shown in the figure


.


296




Refitting

4 Repair


Continued

The procedure below details how to refit gearbox axis 3.

1

Action



Note xx0600003127

• A : O-ring 3HAB 3772-92

2

CAUTION


3

4

5

6

7

8

9

Fit a lifting tool in the uppermost hole of the gearbox and secure it with a roundsling.


Lift the gearbox on to the guide pins and push it to its mounting position.

Refit the gearbox, while the upper arm is resting on its side on the floor.

Refit the upper arm .


Replacement of the upper arm on page 222 .

Fill the gearbox axis 3 with oil.
















297

4 Repair


Continued

Action

10

DANGER



Note

298




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.

xx0600003085

A

B

C

D

E

F

Gearbox, axis 6 (IRB 6620)

Attachment screws, gearbox

Oil plug, draining

Oil plug, filling

Turning disk

Attachment screws, turning disk xx0200000219

A

B

C

D

Gearbox, axis 6 (IRB 6620 Foundry Plus)

Attachment screws and washers

Oil plug, draining

Oil plug, filling





299

4 Repair


Continued


Equipment, etc.

Gearbox

O-ring

O-ring

O-ring

O-ring

Grease

Flange sealant

Standard toolkit



Axis Calibration


-

Art. no.

Note



Includes o-ring.

3HAB3772-58

3HAB3772-57

3HAB3772-64

3HAB3772-61

3HAB3537-1

12340011-116

Must be replaced when reassembling gearbox!

For type 2 of the gearbox.

164.7x3.53

Must be replaced when reassembling gearbox.


150.0x2.0



12 pcs, 13.1x1.6



Loctite 574



.

3HAC15716-1

3HAC055412-001


Required if Calibration

Pendulum is the valid calibration method for the robot.





300




4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, gearbox

The procedure below details how to remove gearbox, axis 6.

1

Action


Note

2

DANGER

Turn off all:





3

4

5

Drain the oil from gearbox, axis 6.

Remove the turning disk .



.


Removing, turning disk on page 214

.

Remove the gearbox by unscrewing its 8 attachment screws.

Shown in the figure


.




301


4 Repair


Continued

6

Action

If required, apply M8 screws to the holes shown in the figure beside to press the gearbox out.

Note

Foundry Plus:

Remove old Loctite 574 flange sealant residues and other contamination from the contact surfaces.

xx0200000220

• A: M8 holes for pressing out the gearbox

7 Remove the gearbox axis 6 by lifting it out carefully.

xx1400001123

Be careful not to damage the motor pinion!

Refitting, gearbox

The procedure below details how to refit gearbox, axis 6.

Action Note

1

DANGER

Turn off all:






302




4 Repair


Continued

2

Action Note

Make sure the o-ring is fitted to the rear of the gearbox. Lubricate the o-ring with grease.



.

3

4 xx0200000221

• A: O-ring, gearbox axis 6

Release the holding brake of motor axis 6.



.

Foundry Plus:


xx1400001122

5 Insert the gearbox, axis 6 into the wrist unit.

6 Secure the gearbox with the attachment screws and washers.

7 Refit the turning disc .



.

Shown in the figure


Make sure the gears of the gearbox mate with the gears of the motor!

Shown in the figure


8 pcs or 18 pcs (depending on wrist version): M8 x 40, 12.9 quality Gleitmo, Tightening torque: 30 Nm.



before fitting.


Refitting, turning disk on page 215 .




303


4 Repair


Continued

8

9

10

Action

Perform a leak-down test .



11

DANGER



.

Note


Performing a leakdown test on page 178 .


Changing oil, axis-

6 gearbox on page 166

.






.

304




5 Calibration

5.1.1 Introduction and calibration terminology

5 Calibration

5.1 Introduction to calibration

5.1.1 Introduction and calibration terminology

Calibration information

This chapter includes general information about the recommended calibration methods and also the detailed procedures for updating the revolution counters, checking the calibration position etc.

Detailed instructions of how to perform Axis Calibration are given on the

FlexPendant during the calibration procedure. To prepare calibration with Axis

Calibration method, see


Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools.

Calibration terminology

Term

Calibration method

Synchronization position

Calibration position

Standard calibration

Fine calibration

Reference calibration

Update revolution counter

Synchronization mark

Definition

A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines.

Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.

Known position of the complete robot that is used for calibration of the robot.

A generic term for all calibration methods that aim to move the robot to calibration position.

A calibration routine that generates a new zero position of the robot.

A calibration routine that in the first step generates a reference to current zero position of the robot. The same calibration routine can later on be used to recalibrate the robot back to the same position as when the reference was stored.

This routine is more flexible compared to fine calibration and is used when tools and process equipment are installed.

Requires that a reference is created before being used for recalibrating the robot.

Requires that the robot is dressed with the same tools and process equipment during calibration as during creation of the reference values.

A calibration routine to make a rough calibration of each manipulator axis.

Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position.




5 Calibration

5.1.2 Calibration methods

5.1.2 Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied by ABB.

Types of calibration

Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration position.

Standard calibration data is found on the SMB

(serial measurement board) or EIB in the robot.

For robots with RobotWare 5.04 or older, the calibration data is delivered in a file, calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position.

Axis Calibration or Calibration Pendulum i

Levelmeter calibration

(alternative method)

Absolute accuracy calibration (optional)

Based on standard calibration, and besides positioning the robot at synchronization position, the Absolute accuracy calibration also compensates for:

• Mechanical tolerances in the robot structure

• Deflection due to load

Absolute accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot.

Absolute accuracy calibration data is found on the SMB (serial measurement board) in the robot.

For robots with RobotWare 5.05 or older, the absolute accuracy calibration data is delivered in a file, absacc.cfg, supplied with the robot at delivery. The file replaces the calib.cfg file and identifies motor positions as well as absolute accuracy compensation parameters.

A robot calibrated with absolute accuracy has a sticker next to the identification plate of the robot.

To regain 100% absolute accuracy performance, the robot must be recalibrated for absolute accuracy!

CalibWare xx0400001197 i

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.


If no data is found related to standard calibration, Calibration Pendulum is used as default.


306




5 Calibration


Continued

Brief description of calibration methods

Calibration Pendulum method

Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).

Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II

• Reference calibration

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum , which describes the method and the different routines further.

Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 6620 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.

The following routines are available for the Axis Calibration method:

• Fine calibration

• Update revolution counters

• Reference calibration

The calibration equipment for Axis Calibration is delivered as a toolkit.

An introduction to the calibration method is given in this manual, see


The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant. You will be guided through the calibration procedure, step by step.

Levelmeter calibration - alternative method

Levelmeter calibration is referred to as the alternative method for calibration of

ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with

Calibration Pendulum.

This method may, after calibration, require modifications in the robot program and is therefore not recommended.

The calibration equipment (Levelmeter 2000) for levelmeter calibration is ordered as separate parts for each robot, and includes the Operating manual - Levelmeter

Calibration , which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute

Accuracy calibration is used as a TCP calibration. The CalibWare tool guides through the calibration process and calculates new compensation parameters.

This is further detailed in the Application manual - CalibWare Field 5.0

.

If a service operation is done to a robot with the option Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance.




307


5 Calibration


Continued

For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in the section


.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum , which describes the method and the different routines further.

308




5 Calibration

5.1.3 When to calibrate

5.1.3 When to calibrate

When to calibrate

The system must be calibrated if any of the following situations occur.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual.

If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors or parts of the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See


. This will occur when:

• The battery is discharged

• A resolver error occurs

• The signal between a resolver and measurement board is interrupted

• A robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller are connected at the first installation.

The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot is changed, it needs to be recalibrated for new resolver values.

If the robot has absolute accuracy calibration, it needs to be calibrated for new absolute accuracy.




309

5 Calibration

5.2.1 Synchronization marks and synchronization position for axes

5.2 Synchronization marks and axis movement directions

5.2.1 Synchronization marks and synchronization position for axes

Introduction

This section shows the position of the synchronization marks and the synchronization position for each axis.

Synchronization marks, IRB 6620

The illustration below shows the positions of the synchronization marks on all axes of the robot.

xx0600003096

A


310

Synchronization mark, axis 1




B

C

D

E

F

5 Calibration

5.2.1 Synchronization marks and synchronization position for axes

Continued









311

5 Calibration

5.2.2 Calibration movement directions for all axes

5.2.2 Calibration movement directions for all axes

Overview

When calibrating, the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on. Positive directions are shown in the graphic below.

Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below.

Manual movement directions, 6 axes

Note!

The graphic shows an IRB 7600. The positive direction is the same for all

6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction!

312 xx0200000089




5 Calibration

5.3 Updating revolution counters

5.3 Updating revolution counters

Introduction

This section describes how to do a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Revolution indicator

The IRB 6620/IRB 6620 LX (not Foundry version) is equipped with a revolution indicator on axis 4.

Location

The revolution indicator is located as shown in figure.

Function xx1500002405

Before doing an update of the revolution counter, the revolution indicator must be checked.

The green side of the indicator shall point towards axis centre.

The indicatior shows if axis 4 is turned correctly or has been rotated more than

±360°. If the indicator has been turned, the robot has to be jogged manually in the





313

5 Calibration


Continued opposite direction to reach the correct position before aligning synchronization marks. If not there is a risk of twisting the cabling.

• When turning axis 4, the indicator will move accordingly, up or down.

xx1500002449

Check indicator before synchonization

1

Action

Make sure that the green side of the indicator is turned towards the axis 4 center.

Note

2 If not:

Jog the robot manually in the opposite direction to reach the correct position.

xx1500002404 xx1500002449


314




5 Calibration


Continued

3

Action

If the indicator moves towards red when jogging, switch to the opposite direction to reach green side.

Note

CAUTION

If axis 4 is turned too much, the red side of the indicator will turn towards axis 4 and the cabling may be damaged. Jog the robot in the opposite direction.

4 xx1500002450

If the red side of the indicator points towards axis

4 centre, make a check that the motor cabling and motor connectors are not damaged. Replace if damaged.

Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.

1

2

3

Action

Select axis-by-axis motion mode.

Note

Jog the manipulator to align the synchronization marks.

See


When all axes are positioned, update the revolution counter.

Step 2 - Updating the revolution counter with the FlexPendant on page 316 .

Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important to make sure that axes 4 and 6 of the following mentioned manipulators are positioned correctly. The axes can be calibrated at the wrong turn, resulting in an incorrect manipulator calibration.

Make sure the axes are positioned according to the correct calibration values, not only according to the synchronization marks. The correct values are found on a label, located either on the lower arm, underneath the flange plate on the base or on the frame.

At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated.

If one of the following mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration





315

5 Calibration


Continued position will be lost due to non-integer gear ratio. This affects the following manipulators:

Manipulator variant

IRB 6620

Axis 4

Yes

Axis 6

No

If the synchronization marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the synchronization marks again (try both directions, if needed).

Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).

1

Action

On the ABB menu, tap Calibration .

xx1500000942


316




5 Calibration


Continued

2

Action

All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

xx1500000943

3 This step is valid for RobotWare 6.02 and later.

Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration.

Tap Manual Method (Advanced) .


3HAC027151-001 Revision: T xx1500000944



317

5 Calibration


Continued

4

Action

A screen is displayed, tap Rev. Counters .

318 en0400000771

5

6

7

Tap Update Revolution Counters...

.

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

Select the axis to have its revolution counter updated by:

• Ticking in the box to the left

• Tapping Select all to update all axes.

Then tap Update .

A dialog box is displayed, warning that the updating operation cannot be undone:

• Tap Update to proceed with updating the revolution counters.

• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the selected revolution counters and removes the tick from the list of axes.

8

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury!

Check the synchronization position very carefully after each update. See

Checking the synchronization position on page 334

.




5 Calibration

5.4.1 Description of Axis Calibration

5.4 Calibrating with Axis Calibration method

5.4.1 Description of Axis Calibration

Instructions for Axis Calibration procedure given on the FlexPendant


This manual contains a brief description of the method, additional information to the information given on the FlexPendant, article number for the tools and images of where to fit the calibration tools on the robot.

Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis at the time. The robot axes are both manually and automatically moved into position, as instructed on the FlexPendant.

A fixed calibration pin/bushing is installed on each robot axis at delivery.

The Axis Calibration procedure described roughly:

• A removable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration, according to instructions on the

FlexPendant.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel.

WARNING

The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.

• During the calibration procedure, RobotWare moves the robot axis chosen for calibration so that the calibration tools get into contact. RobotWare records values of the axis position and repeats the coming-in-contact procedure several times to get an exact value of the axis position.

WARNING

Risk of pinching! The contact force for large robots can be up to 150 kg.

Keep a safe distance to the robot.

• The axis position is stored in RobotWare with an active choice from the operator.




319


5 Calibration


Continued

Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the beginning of the procedure on the FlexPendant.

Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling or equipment fitted to the robot.

Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the robot is dressed with tools, process cabling or other equipment.

Also choose this routine if the robot is suspended.

If calibrating the robot with reference calibration there must be reference values created before repair is made to the robot, if values are not already available.

Creating new values requires possibility to move the robot. The reference values contain positions of all axes, torque of axes and technical data about the tool installed. A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.


When reference calibration is performed, the robot is restored to the status given by the reference values.

Note

Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Validation

When calibrating the robot with the reference calibration routine, the robot must be dressed with the same tools, process cabling and any other equipment as when the reference values were created.

In the mentioned routines, it is also possible to validate the calibration data.

Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to its calibration position during the calibration procedure.

In order for the axis to be able to be moved to calibration position, or in order for getting proper access to the calibration bushing, other axes might need to be jogged to positions different from 0 degrees. Information about which axes are allowed to be jogged will be given on the FlexPendant. These axes are marked with Unrestricted in the FlexPendant window.

How to calibrate a suspended robot

The IRB 6620 is calibrated floor standing in factory, prior to shipping.





5 Calibration


Continued

To calibrate a suspended robot, reference calibration must be used. Reference values for a suspended robot must be created with the robot mounted at its working position, not standing on a floor.

To calibrate a suspended robot with the fine calibration routine, the robot must first be taken down and then be mounted standing on the floor.




321

5 Calibration

5.4.2 Calibration tools for Axis Calibration

5.4.2 Calibration tools for Axis Calibration

Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance, durability and safety in case of accidental damage.

The calibration tool will eventually break from fatigue after longer period of use and then needs to be replaced. There is no risk for bad calibrations as long as the calibration tool is in one piece.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from

ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel.

Equipment, etc.


Axis Calibration

Article number

3HAC055412-001

Note



Examining the calibration tool

Check prior to usage

Before using the calibration tool, make sure that the tube insert, the plastic protection and the steel spring ring are present.

WARNING

If any part is missing or damaged, the tool must be replaced immediately.

xx1500001914

A

B

C

Tube insert

Plastic protection

Steel spring ring


322




5 Calibration

5.4.2 Calibration tools for Axis Calibration

Continued

Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following measures should be checked.

• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on calibration tool size).

• Straightness within 0.005 mm.

xx1500000951

A Outer diameter

Identifying the calibrating tools

It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below.

2

Note

1

The tool identifier is NOT delivered from ABB, it is a customized solution.

Action

It is possible to use any RFID solution, with the correct dimensions. ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices (13.56 Mhz) according to ISO

14443 or ISO 15693.

Note

Note

The maximum dimensions on the RFID chip must not exceed Ø7.9 mm x 8.0 mm, Ø5.9 mm x 8.0

mm or Ø3.9 mm x 8.0 mm (depending on calibration tool size).

There is a cavity on one end of the calibration tool in which the RFID chip can be installed.

Install the RFID chip according to supplier instructions.

Install the chip in flush with the tool end.




5 Calibration

5.4.3 Installation locations for the calibration tools

5.4.3 Installation locations for the calibration tools

Location of fixed calibration items

The figure shows how the robot is equipped with items for installation of calibration tools for Axis Calibration (fixed calibration pins and/or bushings). The figure does not show installed calibration tools.

A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows.

xx1600000001 xx1600000011


324




Spare parts

5 Calibration

5.4.3 Installation locations for the calibration tools

Continued

When calibration is not being performed, a protective cover and an o-ring should always be installed on the fixed calibration pin as well as a protective plug, included a sealing, in the bushing. Replace damaged parts with new, if needed.

Spare part

Protection cover and plug set

Article number

3HAC056806-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.




325

5 Calibration

5.4.4 Axis Calibration - Running the calibration procedure

5.4.4 Axis Calibration - Running the calibration procedure

Required tools

The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance, durability and safety in case of accidental damage.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from

ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel.

Equipment, etc.

Calibration tool box, Axis

Calibration

Article number

3HAC055412-001

Note



Required consumables

Consumable

Clean cloth

Spare parts

Spare part

Protection cover and plug set

-


Article number

3HAC056806-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.

Overview of the calibration procedure on the FlexPendant


Use the following list to learn about the calibration procedure before running the

RobotWare program on the FlexPendant. It gives you a brief overview of the calibration procedure sequence.

After the calibration method has been called for on the FlexPendant, the following sequence will be run.

1 Choose calibration routine. The routines are described in

Routines in the calibration procedure on page 320

.

2 Choose which axis/axes to calibrate.

3 The robot moves to synchronization position.

4 Validate the synchronization marks.

5 The robot moves to preparation position.

6 Remove the protective cover from the fixed pin and the protection plug from the bushing, if any, and install the calibration tool.





5 Calibration


Continued

7 The robot performs a measurement sequence by rotating the axis back and forth.

8 Remove the calibration tool and reinstall the protective cover on the fixed pin and the protection plug in the bushing, if any.

9 The robot moves to verify that the calibration tool is removed.

10 Choose whether to save the calibration data or not.

Calibration of the robot is not finished until the calibration data is saved, as last step of the calibration procedure.

Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.

Action Note

1

DANGER

While conducting the calibration, the robot needs to be connected to power.

Make sure that the robots working area is empty, as the robot can make unpredictable movements.

2 Wipe the calibration tool clean.

Use a clean cloth.

Note

The calibration method is exact. Dust, dirt or color flakes will affect the calibration value.

Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.

1

Action

On the ABB menu, tap Calibration .

Note xx1500000942





327

5 Calibration


Continued

2

Action

All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

Note xx1500000943

3 Calibration method used at factory for each axis is shown, as well as calibration method used for the robot during last field calibration.

Tap Run Calibration Method . The software will automatically call for the procedure for the valid calibration method.

The FlexPendant will give all information needed to proceed with Axis

Calibration.

xx1500000944

4 Follow the instructions given on the FlexPendant.

A brief overview of the sequence that will be run on the FlexPendant is given in

Overview of the calibration procedure on the FlexPendant on page 326 .

Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished, the RobotWare program needs to be started again. Use this procedure to take required action.

Situation Action

The three-position enabling device on the

FlexPendant has been released during robot movement.

Press and hold the three-position enabling device and press Play .





5 Calibration


Continued

Situation

The RobotWare program is terminated with

PP to Main .

Action

Remove the calibration tool, if it is installed, and restart the calibration procedure from the beginning. See

Starting the calibration procedure on page 327

.

If the calibration tool is in contact the robot axis needs to be jogged in order to release the calibration tool. Jogging the axis in wrong direction will cause the calibration tool to break. Directions of axis movement is shown in

Calibration movement directions for all axes on page 312

Axis Calibration with SafeMove option

To be able to run Axis Calibration SafeMove needs to be unsynchronized. The Axis

Calibration routine recognizes if the robot is equipped with SafeMove and will force

SafeMove to unsynchronize automatically.

However, SafeMove may generate other warning messages anytime during the

Axis Calibration routine.

Safety controller not synchronized - SafeMove message

1

Action

SafeMove generates the message "Safety controller not synchronized".

Note

2

3 xx1500002480

Confirm unsynchronized state by pressing Acknowledge to continue Axis Calibration procedure.

Restart Axis Calibration procedure by pressing

Play .





329

5 Calibration


Continued

Unsynchronized speed exceeded - SafeMove message while saving robot data

1

Action

SafeMove generates the message "Unsynchronized speed exceeded" while saving robot data.

Note xx1500002481

2

3

Press Acknowledge to continue Axis Calibration procedure.


Play .

Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine

1

Action

SafeMove generates the message "Unsynchronized time limit expired" (anytime).

Note

2

3 xx1500002482

Press OK to continue Axis Calibration procedure.


Play .


330




5 Calibration


Continued

After calibration

1

2

Action

Check the o-ring on the fixed calibration pin.

Replace if damaged or missing.

Reinstall the protective cover on the fixed calibration pin on each axis, directly after the axis has been calibrated.

Replace the cover with new spare part, if missing or damaged.

Note

3 Reinstall the protective plug and sealing in the bushing on each axis, directly after the axis has been calibrated. Ensure that the sealing is not damaged.

Replace the plug and the sealing with new spare part, if missing or damaged.

xx1600002102

Protection cover and plug set:

3HAC056806-001.

xx1500000952

Protection cover and plug set:

3HAC056806-001.




331

5 Calibration

5.5 Calibrating with Calibration Pendulum method

5.5 Calibrating with Calibration Pendulum method

Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools.

332




5 Calibration

5.6 Verifying the calibration

5.6 Verifying the calibration

Introduction

Always verify the results after calibrating any robot axis to verify that all calibration positions are correct.

Verifying the calibration

Use this procedure to verify the calibration result.

1

2

3

4

Action Note

Run the calibration home position program twice.

Do not change the position of the robot axes after running the program!

See

Checking the synchronization position on page 334 .

Adjust the synchronization marks when the calibration is done, if necessary.



Write down the values on a new label and stick it on top of the calibration label.

The label is located on the lower arm.

Remove any calibration equipment from the robot.




333

5 Calibration

5.7 Checking the synchronization position

5.7 Checking the synchronization position

Introduction

Check the synchronization position of the robot before beginning any programming of the robot system. This may be done:

• Using a MoveAbsJ instruction with argument zero on all axes.

• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their synchronization position.

1

2

3

4

Action

On ABB menu tap Program editor .

Create a new program.

Use MoveAbsJ in the Motion&Proc menu.

Create the following program:

MoveAbsJ [[0,0,0,0,0,0],

[9E9,9E9,9E9,9E9,9E9,9E9]]

\NoEOffs, v1000, fine, tool0

Note

5

6

Run the program in manual mode.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See


and


Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.

1

2

3

4

5

Action

On the ABB menu, tap Jogging .

Note

Tap Motion mode to select group of axes to jog.

Tap to select the axis to jog, axis 1, 2, or

3.

Manually run the robots axes to a position where the axis position value read on the

FlexPendant, is equal to zero.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See


and


334




6 Decommissioning

6.1 Environmental information


6.1 Environmental information

Symbol

The following symbol indicates that the product must not be disposed of as common garbage. Handle each product according to local regulations for the respective content (see table below).

xx1800000058

Hazardous material

The table specifies some of the materials in the product and their respective use throughout the product.

Dispose components properly according to local regulations to prevent health or environmental hazards.

Material

Batteries, NiCad or Lithium

Copper

Cast iron/nodular iron

Steel

Neodymium

Plastic/rubber

Oil, grease

Aluminium

Nickel

Example application

Serial measurement board

Cables, motors

Base, lower arm, upper arm

Gears, screws, base frame, and so on.

Brakes, motors

Cables, connectors, drive belts, and so on.

Gearboxes

Covers, synchronization brackets

Turning disc (foundry)

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration must be carried out under controlled conditions in accordance with local regulations.




335



6.1 Environmental information

Continued

Also note that:

• Spills can form a film on water surfaces causing damage to organisms.

Oxygen transfer could also be impaired.

• Spillage can penetrate the soil causing ground water contamination.

336





6.2 Scrapping of robot

6.2 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries:

• Always remove all batteries. If a battery is exposed to heat, for example from a blow torch, it will explode.

• Always remove all oil/grease in gearboxes. If exposed to heat, for example from a blow torch, the oil/grease will catch fire.

• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed.




337


7 Reference information

7.1 Applicable standards


7.1 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased out or replaced standards are removed from the list when needed.

Standards, EN ISO

The product is designed in accordance with the requirements of:

Standard

EN ISO 12100:2010

EN ISO 13849-1:2015

EN ISO 13850:2015

EN ISO 10218-1:2011

Description

Safety of machinery - General principles for design - Risk assessment and risk reduction

Safety of machinery, safety related parts of control systems -

Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Robots for industrial environments - Safety requirements -Part

1 Robot

ISO 9787:2013

ISO 9283:1998

EN ISO 14644-1:2015

EN ISO 13732-1:2008 i

Robots and robotic devices -- Coordinate systems and motion nomenclatures

Manipulating industrial robots, performance criteria, and related test methods

Classification of air cleanliness

Ergonomics of the thermal environment - Part 1

EMC, Generic emission EN 61000-6-4:2007 +

A1:2011

IEC 61000-6-4:2006 +

A1:2010

(option 129-1)

EN 61000-6-2:2005

IEC 61000-6-2:2005

EN IEC 60974-1:2012 ii

EN IEC 60974-10:2014

ii

EMC, Generic immunity

Arc welding equipment - Part 1: Welding power sources

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part

1 General requirements i ii

IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)

Only robots with protection Clean Room.

Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard

EN 614-1:2006 + A1:2009

Description

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles




339



7.1 Applicable standards

Continued

Standard

EN 574:1996 + A1:2008

Description

Safety of machinery - Two-hand control devices - Functional aspects - Principles for design

Other standards

Standard

ANSI/RIA R15.06

ANSI/UL 1740

CAN/CSA Z 434-14

Description

Safety requirements for industrial robots and robot systems

Safety standard for robots and robotic equipment

Industrial robots and robot Systems - General safety requirements

340





7.2 Unit conversion

7.2 Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity

Length

Weight

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 g

1 bar

1 N

1 Nm

1 L

3.28 ft.

2.21 lb.

0.035 ounces

100 kPa

0.225 lbf

0.738 lbf-ft

0.264 US gal

39.37 in

14.5 psi




341


7.3 Screw joints

7.3 Screw joints

General

This section describes how to tighten the various types of screw joints on the IRB

6620.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints.

It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed. Using other types of screws will void any warranty and may potentially cause serious damage or injury.

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1 Apply lubricant to the screw thread.

2 Apply lubricant between the plain washer and screw head.

3 Screw dimensions of M8 or larger must be tightened with a torque wrench.

Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.

Lubricant

Molycote 1000 (molybdenum disulphide grease)

Article number

11712016-618

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the following tables. Any special torques are specified in the repair, maintenance or installation procedure descriptions.

Any special torque specified overrides the standard torque!

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.






7.3 Screw joints

Continued

• Always tighten the joint by hand, and never use pneumatic tools.

• Use the correct tightening technique , that is do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10% !

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Note

A special torque specified in the repair, maintenance or installation procedure overrides the standard torque.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with allen head screws.

Note


Dimension

M5

M6

M8

M10

M12

M16

M20

M24

10

24

47

82

Tightening torque (Nm)

Class 8.8, oil-lubricated

Tightening torque (Nm) Tightening torque (Nm)



6 -

-

34

67

115

-

40

80

140

200

400

680

290

560

960

340

670

1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head screws.

Note

Dimension

M8


Class 10.9, lubricated i

28





Class 12.9, lubricated

i

35


343



7.3 Screw joints

Continued

Dimension Tightening torque (Nm)

Class 10.9, lubricated i


Class 12.9, lubricated

i

M10

M12

M16

55

96

235

70

120

280

M20 460 550 i

M24 790 950

Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass .

Note


1/8

1/4

3/8

1/2

3/4

Dimension

15

20

40

70

Tightening torque Nm -

Nominal


Min.


Max.

12 8 15

10

15

30

55

20

25

50

90

344





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 highlighted in this way.

To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

Example

Following is an example of a weight specification in a procedure:

Action Note

CAUTION

The robot weighs 900 kg.





345


7.5 Standard tools

7.5 Standard tools

General

All service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standard toolkit and defined in the following table.

This way, the tools required are the sum of the standard toolkit and any tools listed in the instruction.

Contents, standard toolkit

1

1

1

1

1

1

1

2

1

1

1

1

Qty Tool

Ring-open-end spanner 8-19 mm

Socket head cap 5-17 mm

Torx socket no: 20-60

Box spanner set

Rem.

Torque wrench 10-100 Nm

Torque wrench 75-400 Nm

Ratchet head for torque wrench 1/2

Hexagon-headed screw M10x100

Hex bit socket head cap no. 14 socket 40 mm L=100 mm

Hex bit socket head cap no. 14 socket 40 mm L=20 mm To be shortened to 12 mm

Hex bit socket head cap no. 6 socket 40 mm L=145 mm

Hex bit socket head cap no. 6 socket 40mm bit L=220 mm

346





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 the section


, and of special tools, listed directly in the instructions and also gathered in this section.

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.

Always use the same calibration method as used at the factory.



Description


Art. no.

3HAC15716-1

Note


Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating the robot with the Axis Calibration method.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.

Always use the same calibration method as used at the factory.



Description Art. no.


3HAC055412-

001

Note



Basic tools

The following table specifies the tools in the basic toolkit that are used for the current robot model. This toolkit is necessary primarily 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



2

2

Qty

1

Art. no.

3HAC12342-1

3HAC15520-1

3HAC15520-2


347



7.6 Special tools

Continued

Description



Lifting tool, motor ax 1

Lifting tool, motor ax 2, 3

Removal tool, motor M10x

Removal tool, motor M12x

Rotation tool 1

Standard toolkit (content described in section


)

1

1

2

Qty

2

2

1

Art. no.

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

The following table 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.

Description

Lifting tool

Hoisting block

Lifting chain (used together with the hoisting block)

Support, base and gear axis 1

Qty

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

Art. no.

3HAC026597-001

3HAC15535-1

3HAC15556-1

3HAC025333-005

3HAC025214-001

3HAC022637-001

3HAC14457-1

348





7.7 Lifting accessories and lifting instructions

7.7 Lifting accessories and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure.

The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.

This implies that the instructions delivered with the lifting accessories should be stored for later reference.




349


8 Spare part lists

8.1 Spare part lists and illustrations

8 Spare part lists

8.1 Spare part lists and illustrations

Location

Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.myportal.abb.com

.




351


9 Circuit diagram

9.1 Circuit diagrams


9.1 Circuit diagrams

Overview

The circuit diagrams are not included in this manual, but are available for registered users on myABB Business Portal, www.myportal.abb.com

.

See the article numbers in the tables below.

Controllers

Product

Circuit diagram - IRC5

Circuit diagram - IRC5 Compact

Article numbers for circuit diagrams

3HAC024480-011

3HAC049406-003

Circuit diagram - IRC5 Panel Mounted Controller

3HAC026871-020

Circuit diagram - Euromap 3HAC024120-004

Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product

Circuit diagram - IRB 120

Circuit diagram - IRB 140 type C








Circuit diagram - IRB 1600/1660




Circuit diagram - IRB 4400/4450S


Circuit diagram - IRB 6400RF

Circuit diagram - IRB 6600 type A

Circuit diagram - IRB 6600 type B




3HAC031408-003

3HAC6816-3

3HAC025611-001

3HAC028647-009

3HAC036446-005

3HAC025691-001

3HAC025691-001

3HAC046307-003

3HAC2800-3

3HAC021351-003

3HAC039498-007

3HAC6670-3

3HAC029570-007

3HAC9821-1

3HAC029038-003

3HAC8935-1

3HAC13347-1

3HAC025744-001

3HAC13347-1

3HAC025744-001


353



9.1 Circuit diagrams

Continued

Product


Circuit diagram - IRB 6620 / IRB 6620LX


Circuit diagram - IRB 6650S





Circuit diagram - IRB 910SC


3HAC025090-001

3HAC025090-001

3HAC025744-001

3HAC13347-1

3HAC025744-001

3HAC025744-001

3HAC029940-001

3HAC043446-005

3HAC13347-1

3HAC025744-001

3HAC050778-003

3HAC056159-002

354




Index

Index

A

Absolute Accuracy, calibration, 307

additional mechanical stop location, 141

aluminum

disposal, 335

ambient humidity

operation, 60 storage, 60

ambient temperature


assembly instructions, 47

assessment of hazards and risks, 18

Axis Calibration, 319

calibration tool

article number, 322, 326

examining, 322

installation position, 324

overview of method, 319

procedure on FlexPendant, 326 protective cover and protection plug, 324, 326

B base plate

guide pins, 82 securing, 82

batteries

disposal, 335

handling, 36

battery pack

replacing, interval, 118

brake release, 79

brake release board, replacement, 238

brakes

testing function, 35

buttons for brake release, 79

C

cabinet lock, 24, 30

cable harness attachments, 134

cabling, robot, 112 cabling between robot and controller, 112

calibrating

robot, 319

roughly, 313

calibrating robot, 319

calibration

Absolute Accuracy type, 306

alternative method, 307

Levelmeter calibration, 307

rough, 313

standard type, 306

verification, 333

when to calibrate, 309

calibration, Absolute Accuracy, 307

calibration manuals, 308

calibration marks, 310

calibration position

jogging to, 334

scales, 310 calibration scales, 310

CalibWare, 306

carbon dioxide extinguisher, 21

cast iron




disposal, 335

changing oil

axis 1, 151

cleaning, 173

climbing on robot, 24

Cold environments, 114

complete arm system, replacement, 202

connecting the robot and controller, cabling, 112

connection

external safety devices, 25

copper

disposal, 335

D

damage to additional mechanical stop, 141

damage to mechanical stop, 139

danger levels, 39

dimensions

frame, 100

lower arm, 96

turning disk, 102

upper arm, 98

direction of axes, 312

E

enabling device, 29

environmental information, 335

equipment on robot, 96

ESD

damage elimination, 32 sensitive equipment, 32

expected life, 119

external safety devices, 25

extra equipment

fastener quality, 103

frame, 100

lower arm, 96 robot, 96

turning disk, 102

upper arm, 98

F

fastener quality for extra equipment, 103

fire extinguishing, 21

fitting equipment on robot, 96

fitting fork lift, 66

FlexPendant

jogging to calibration position, 334

MoveAbsJ instruction, 334

updating revolution counters, 316

fork lift, 69

foundation

requirements, 59

frame

dimensions, 100

G gearbox

oil change axis 1, 151

gearbox axis 6, replacement, 299

gearboxes

location of, 149

Gravity Alpha, 92

Gravity Beta, 91

grease

disposal, 335

guide pins, base plate, 82

355

Index

H hanging

installed hanging, 24

hazardous material, 335

height

installed at a height, 24

hold-to-run, 29

HRA, 18

humidity


I

information labels location, 137

inspecting

additional mechanical stop, 141

cable harness, 134

information labels, 137

mechanical stop, 139

inspecting oil levels

axis-6, 131

axis-5, 129

axis-4, 127

axis-3, 125

axis-2, 122

axis-1, 120

installation

mechanical stop axis 1, 107


installing equipment on robot, 96

instructions for assembly, 47

integrator responsibility, 17

intervals for maintenance, 117

L labels

robot, 41

leak-down test, 178

Levelmeter calibration, 307

lifting accessory, 345

lifting robot

with fork lift, 69

with roundslings, 77

limitation of liability, 17

Lithium

disposal, 335

loads on foundation, 58

lower arm

dimensions, 96

lubrication

amount in gearboxes, 149 type of lubrication, 149

M magnesium

disposal, 335

maintenance schedule, 117

manually releasing brakes, 79

mechanical stop

axis 1, 107

axis 3, 109

mechanical stop location, 139

motor axis 1, replacement, 242





356


MoveAbsJ instruction, 334

N

nation specific regulations, 17

negative directions, axes, 312

neodymium

disposal, 335

NiCad

disposal, 335

nodular iron

disposal, 335

O oil

amount in gearboxes, 149

disposal, 335

type of oil, 149

oil change

axis 1, 151

safety risks, 37

oil level

gearbox axis-6, 131

gearbox axis-5, 129

gearbox axis-4, 127

gearbox axis-3, 125

gearbox axis-2, 122

gearbox axis-1, 120

operating conditions, 60

P pedestal

installed on pedestal, 24

plastic

disposal, 335

positive directions, axes, 312

product standards, 339

protection classes, 60 protection type, 60

protective equipment, 25 protective wear, 25

R

region specific regulations, 17

release brakes, 22

replacement

brake release board, 238

complete arm system, 202

gearbox axis 6, 299

motor axis 1, 242

motor axis 2, 247

motor axis 3, 253

motor axis 4, 260

motor axis 5, 265

motor axis 6, 270

turning disk, 213

replacing

SMB battery, 169

requirements on foundation, 59

responsibility and validity, 17

restricting

working range axis 1, 107

working range axis 3, 109

revolution counters

storing on FlexPendant, 316

updating, 313

risk of tipping, 65




robot

labels, 41

protection class, 60 protection types, 60

symbols, 41

rubber

disposal, 335

S safety

brake testing, 35

ESD, 32

fire extinguishing, 21

moving robots, 26

release robot axes, 22

signal lamp, 105

signals, 39 signals in manual, 39 symbols, 39

symbols on robot, 41

test run, 27

working range, 28

safety equipment

mechanical stop, 107


signal lamp, 146

safety fence, 18

safety risk

electric parts, 30

hot parts, 33

hydraulic system, 34

installation, 24

oil change, 37

operational disturbance, 24

pneumatic system, 34

service work, 24

voltage, 30

safety signals

in manual, 39

safety standards, 339

safety zones, 18

scales on robot, 310

schedule for maintenance, 117

screw joints, 342

securing

base plate, 82

securing, robot, 87 securing the robot to foundation, attachment screws, 87

signal lamp, 105

signals

safety, 39

SMB battery

replacement, 169

special tools, 347

speed

adjusting, 114

stability, 65

standards, 339

ANSI, 340

CAN, 340

EN, 339

EN IEC, 339

EN ISO, 339

start of robot in cold environments, 114

steel

disposal, 335

storage conditions, 60

suspended mounting, 91

symbols

safety, 39

synchronization position, 315

sync marks, 310

system integrator requirements, 17

system parameter

Gravity Alpha, 92

Gravity Beta, 91

T temperatures


testing

brakes, 35

three-position enabling device, 29

tilted mounting, 91

tools

Axis Calibration, 347

Calibration Pendulum, 347 for service, 347

torques on foundation, 58

transporting the robot, 54 transport support, 54

turning disk dimensions, 102

turning disk replacement, 213

U

updating revolution counters, 313

upper arm

dimensions, 98

V

validity and responsibility, 17

velocity

adjusting, 114

verifying calibration, 333

W

weight, 58

base plate, 81, 86

lower arm, 231

motor, 245, 256–257

robot, 71, 77, 345

upper arm, 224–225

working range

restricting axis 1, 107

restricting axis 3, 109

Z zero position

checking, 334

Index




357

ABB AB, Robotics

Robotics and Motion

S-721 68 VÄSTERÅS, Sweden

Telephone +46 (0) 21 344 400

ABB AS, Robotics


Nordlysvegen 7, N-4340 BRYNE, Norway

Box 265, N-4349 BRYNE, Norway

Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion

No. 4528 Kangxin Highway

PuDong District

SHANGHAI 201319, China

Telephone: +86 21 6105 6666

ABB Inc.


1250 Brown Road

Auburn Hills, MI 48326

USA

Telephone: +1 248 391 9000 abb.com/robotics


ABB IRB 6620 Product Manual

Product manual

Table of contents

Overview of this manual

Product documentation

How to read the product manual

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference information

8 Spare part lists

9 Circuit diagram

Index

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Table of contents