ABB IRB 6660, IRB 6660 - 100/3.3 Product Manual

ROBOTICS

Product manual

IRB 6660

Trace back information:

Workspace R18-2 version a18

Checked in 2018-11-20

Skribenta version 5.3.012

Product manual

IRB 6660 - 100/3.3

IRB 6660 - 130/3.1

IRB 6660 - 205/1.9

IRC5

Document ID: 3HAC028197-001

Revision: S

© Copyright 2007-2018 ABB. All rights reserved.

Specifications subject to change without notice.

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

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

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

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

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.



ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents


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

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

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

9

15

17

1 Safety

1.1

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

1.1.1

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

1.1.2

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

1.2

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

1.2.1

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

1.2.2

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

1.2.3

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

1.3

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

1.3.1

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

1.3.2

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

1.3.3

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

1.3.4

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

1.3.5

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

1.3.6

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

1.3.7

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

1.3.8

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

1.3.9

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

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

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

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

1.4

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

1.4.1

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

1.4.2

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

19

30

31

33

34

25

27

28

29

22

23

24

25

19

19

21

22

35

36

37

38

40

40

42

2 Installation and commissioning 49

2.1

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

2.2

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

2.2.1

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

2.2.2

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

2.2.3

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

2.3

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

2.3.1

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

2.3.2

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

2.3.3

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

2.3.4

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

2.3.5

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

2.3.6

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

2.3.7

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

2.3.8

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

2.3.9

Installation of chip protection - IRB 6660 - 205/1.9 .........................................

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

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

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

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

2.4

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

2.4.1

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

2.4.2

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

2.4.3

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

2.5

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

2.5.1

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

2.6

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

81

84

88

90

69

73

75

76

58

60

60

66

49

50

50

54

97

98

99

100

100

101

103

104

104

107

Product manual - IRB 6660

3HAC028197-001 Revision: S

5



3 Maintenance 109

3.1

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

3.2

Maintenance schedule and 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

Inspecting, oil level gearbox axes 2 - 3 .......................................................

3.3.3


3.3.4


3.3.5


3.3.6

Inspecting, balancing device bearings and piston rod guide ring ......................

3.3.7

Inspection, 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 (option) .................................................................

3.4

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

3.4.1

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

3.4.2

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

3.4.3

Changing oil, gearbox axes 2 and 3 ...........................................................

3.4.4


3.4.5


3.4.6


3.4.7

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

3.5

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

3.5.1

Lubricating balancing device bearings and piston rod ....................................

3.6

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

3.6.1

Cleaning the IRB 6660 ..............................................................................

156

159

162

166

166

169

169

138

140

142

144

144

146

149

153

116

119

121

123

126

130

134

136

109

110

110

111

113

114

114

4 Repair 173

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 1-3) ......................................

4.3.2

Replacement of process cable package 1 - 3 MH ..........................................

4.3.3

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

4.3.4

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

4.3.5

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

4.4

Upper and lower arms ........................................................................................

4.4.1

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

4.4.2

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

4.4.3

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

4.4.4

Replacing the parallel rod .........................................................................

4.4.5

Replacing the complete lower arm ..............................................................

4.4.6

Replacement of parallel arm ......................................................................

4.5

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

4.5.1

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

4.5.2

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

4.5.3

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

181

189

196

204

207

217

217

221

173

174

174

175

177

179

180

181

227

238

244

252

259

259

262

266

6





4.6

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

4.6.1

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

4.6.2

Replacing motors, axes 2 and 3 .................................................................

4.6.3

Replacement of motor, axis 4 ....................................................................

4.6.4

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

4.6.5

Replacement of motor, axis 6 ....................................................................

4.7

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

4.7.1

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

4.7.2

Replacing the gearbox, axes 2- 3 ...............................................................

4.7.3

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

274

274

281

292

297

303

311

311

324

336

5 Calibration 341

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

352

352

354

356

357

363

364

365

341

341

342

344

345

345

347

348

6 Decommissioning 367

6.1

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

6.2

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

6.3

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

6.4

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

367

368

369

370

7 Reference information 373

7.1

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

7.2

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

7.3

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

7.4

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

7.5

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

7.6

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

7.7

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

7.8

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

373

374

376

377

380

381

382

385

8 Spare part lists 387

8.1

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

387

9 Circuit diagram 389

9.1

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

389

Index 391




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.

The manual also contains reference information for all procedures detailed in the manual.

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.

Product manual scope

The manual covers covers all variants and designs of the IRB 6660. Some variants and designs may have been removed from the business offer and are no longer available for purchase.

Organization of chapters

The manual is organized in the following chapters:

Chapter

Safety

Contents

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

Installation and commissioning

Required information about lifting and installation of the robot.

Maintenance 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.



Continues on next page

9



Continued

Chapter

Repair

Calibration

Decommissioning

Reference information

Spare part / part list

Exploded views

Circuit diagram

Contents

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

Calibration procedures and general information about calibration.

Environmental information about the robot and its components.

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

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

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

Reference to the circuit diagram for the robot..

References

Reference

Product specification - IRB 6660

Document ID

3HAC028207-001

Product manual, spare parts - IRB 6660

Circuit diagram - DressPack 6660

Circuit diagram - IRB 6660

Product manual - IRC5

IRC5 with main computer DSQC 639.

Product manual - IRC5

IRC5 with main computer DSQC1000.

Operating manual - IRC5 with FlexPendant

3HAC049112-001

3HAC029940-001


3HAC021313-001

3HAC047136-001

Operating manual - Calibration Pendulum

Operating manual - Service Information System

3HAC050941-001

3HAC16578-1

3HAC050944-001

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

Technical reference manual - Lubrication in gearboxes

Technical reference manual - System parameters

Application manual - Electronic Position Switches

Application manual - CalibWare Field 5.0

3HAC042927-001

3HAC050948-001

3HAC050996-001

3HAC030421-001

Revisions

-

Revision

A

Description

First edition

This revision includes the following additions and/or changes:

• Robot version IRB 6660 - 205/1.9 added which includes new upper arm and new lower arm , as well as Chip protection .

• Process cable package added.

• Option Base spacers no longer available for this robot model. Section is removed from the manual.

• Prerequisites in section Overview changed.

• Oil change intervals for Shell Tivela S 150 is changed.


10 Product manual - IRB 6660




Continued

Revision

B

C

D

E

F



Description

• New product name Mobilgear 600 XP 320 (old name Mobile Gearlube

X 320). Art. no. remains the same.

• Procedure for Process cable package 1-3 MH added.


• The product name RobotStudio Online is changed to RobotStudio.

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

• The oil Shell Tivela S150 has been replaced by Kyodo Yushi TMO150.

• Section Type of oil in gearboxes in chapter Maintenance has been updated according to changes made in oil types.

• 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.

This revision include the following addition:

• New WARNING!

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

• New WARNING!

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

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

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

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

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


• The lifetime of certain parts has been updated, see

Expected component life on page 113 .

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

Circuit diagram on page 389 .

• List of standards updated, see

Applicable standards on page 374 .

The chapter Safety updated with:

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

Safety signals in the manual on page 40 .

• New safety labels on the manipulators, see

Safety symbols on product labels on page 42

.

• Revised terminology: robot replaced with manipulator .

This revision includes the following updates:

• Maximum deviation changed, see

Securing the base plate on page 76 .

This revision includes following additions and/or changes:

• Removed information about lubricating attachment screws, section

Inspecting the additional mechanical stops on page 138 .

• Changed tightening torque of fork lift adapters, from 60 Nm to 270 Nm, see section

Lifting robot with fork lift on page 62 .

• Information about restricting and extending the working range of axis

1 is now separated, see

Mechanically restricting the working range of


11



Continued

Revision

G

H

Description

axis 1 on page 101

and the new section

Extended working range, axis

1 (option 561-1) on page 103 . Also added signal about option 561-1 in

section

Inspecting the axis-1 mechanical stop pin on page 136 .


• Added section

Extended working range, axis 1 (option 561-1) on page 103 .

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

How to read the product manual on page 17 .

• Added instructions for securing parallel arm and lower arm to each other before removing the lower arm, see

Replacing the complete lower arm on page 244

.

• Added guide sleeves to hold the axes 2/3 sealing in place when refitting the lower arm, see


.

• Made minor corrections and improvements in the complete instruction for how to replace the lower arm system, see

Replacing the complete lower arm on page 244 .

• Made minor corrections and improvements in the complete instruction for how to replace the parallel arm, see

Replacement of parallel arm on page 252

.

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

Replacing the axis 1 gearbox on page 311

.

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

Screw joints on page 377

.

• Added

Safety risks during handling of batteries on page 37

.

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

Securing the base plate on page 76

.

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

Securing the base plate on page 76

.

• Corrections and improvements are made in the instruction for how to replace the axis-2 and axis-3 gearbox, see

Replacing the gearbox, axes

2- 3 on page 324

.

• 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 144

.

• Corrected the article number for the o-ring in axis-6 gearbox, see

Replacement of gearbox, axis 6 on page 336 .


• New variant IRB 6660 - 100/3.3 is added.

• Added turning radius and wrist center positions to the working range information, see

Working range and type of motion on page 54

.

• New spare part number for the cable harness for robot variant IRB

6660 - 130/3.1, see Spare parts - cable harness .

• Added complete axis 4 and upper arm extenders to the spare part list, and removed upper arm and cooling elements as spare parts, see

Spare parts - upper arm .

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

Inspecting the oil level in axis-6 gearbox on page 123

.

• Added o-rings to required equipment lists in

Replacing motor, axis 1 on page 274

and

Replacing motors, axes 2 and 3 on page 281

.

• Corrected the position numbers of axis-3 motor and its attachments, see Spare parts - frame to lower arm .

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






Continued

Revision

J

K

L

M

N

P

Q

Description


• Instruction for inspection of oil level updated.

• Added cabling to cooling fan for axis-1 and axis-2 motors.

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

Scrapping of robot on page 369 .

• Spare parts and exploded views are not included in this document but delivered as a separate document. See Product manual, spare parts - IRB 6660


• 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 196

.

• Information about option Foundry Plus implemented in chapter Repair.

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

Replacement of cable harness, lower end (axes 1-3) on page 181 .

• Minor corrections.


• Illustrations of SMB battery RMU improved.


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

Calibration on page 341

.

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.

• Information about grounding point added. See

Robot cabling and connection points on page 104 .


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

• Information about minimum resonance frequency added.

• Bending radius of 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 107

added.

• Updated information regarding replacement of brake release board.

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

• Updated information regarding replacing the balancing device.


• Information added about fatigue to Axis Calibration tool, see

Calibration tools for Axis Calibration on page 354 .

• Added sections in General procedures.

• Safety restructured.

• Updated spare parts number brake release board (is DSQC1050, was

DSQC563)

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

• Moved position of customer cabling plate at robot base to new location, see

Replacement of process cable package 1 - 3 MH on page 189

.




13



Continued

Revision

R

S

Description

• Information about myABB Business Portal added.

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


• Removed doubled information.


• Updated references.

14




Product documentation


Categories for user documentation from ABB Robotics

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

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

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

.

Product manuals

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

• Safety information.

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

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

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

• Calibration.

• Decommissioning.

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

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

• References to circuit diagrams.

Technical reference manuals

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

Application manuals

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

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

An application manual generally contains information about:

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

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

• How to install included or required hardware.

• How to use the application.

• Examples of how to use the application.





15


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.

16




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 19

.

Illustrations

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

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



17



1 Safety

1.1.1 Limitation of liability

1 Safety

1.1 General safety information

1.1.1 Limitation of liability

Limitation of liability

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

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

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

• Use of the robot in other ways than intended.

• Incorrect operation or maintenance.

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

• When instructions for operation and maintenance are not followed.

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

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

• Foreign objects.

• Force majeure.

Nation/region specific regulations

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

To be observed by the supplier of the complete system

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

When integrating the robot with external devices and machines:

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

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





19

1 Safety

1.1.1 Limitation of liability

Continued

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

Note

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

Safe access

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

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

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

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

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

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

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

Robot motion in the Product specification ).

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

Safe handling

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

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

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

Safe design

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

Grippers/end effectors must be designed so that they do not drop work pieces/tools in the event of a power failure or a disturbance to the controller.

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

20




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.




21

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.

22




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 73 .

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.




23

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.

24




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.




25


1 Safety

1.3.1 Safety risks during installation and service work on robots

Continued

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

Spare parts and special equipment

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

Connection of external safety devices

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

Personal protective equipment

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

Allergenic material

See

Environmental information on page 368

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

26




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.




27

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.

28




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.




29

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 .

30




1 Safety

1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

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

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

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

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

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

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

Voltage related risks, IRC5 controller

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

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

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

• The main supply/main switch

• The transformers

• The power unit

• The control power supply (230 VAC)

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

• The drive unit (400/700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

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

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

• Additional connections.

Voltage related risks, manipulator

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

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

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

VAC).




31


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.

32




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

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.




33

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.

34




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.




35

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.

36




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 50

.




37

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.


38




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.




39

1 Safety

1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

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

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

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

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

Danger levels

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

Symbol Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Significance

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

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

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

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

ELECTROSTATIC

DISCHARGE (ESD)

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


40




Symbol Designation

NOTE

1 Safety

1.4.1 Safety signals in the manual

Continued

Significance

Describes important facts and conditions.

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




41

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 42

.

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

French).

Symbols on safety labels

Symbol xx0900000812 xx0900000811

Description

Warning!

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

Caution!

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

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

Prohibition

Used in combinations with other symbols.

xx0900000839





Symbol xx0900000813

1 Safety


Continued

Description

See user documentation

Read user documentation for details.

Which manual to read is defined by the symbol:

• No text: Product manual .

• EPS: Application manual - Electronic Position Switches .

Before disassemble, see product manual xx0900000816

Do not disassemble

Disassembling this part can cause injury.

xx0900000815

Extended rotation

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

xx0900000814 xx0900000808

Brake release

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





43

1 Safety


Continued

Symbol Description

Tip risk when loosening bolts

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

xx0900000810 xx1500002402

Crush

Risk of crush injuries.

xx0900000817


44




Symbol

1 Safety


Continued

Description

Heat

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

!

xx1300001087

1 xx0900000819

3

4

5

2

6

Moving robot

The robot can move unexpectedly.

xx1000001141

2

4

3

1 xx1500002616





45

1 Safety


Continued

Symbol Description

Brake release buttons xx0900000820 xx1000001140 xx0900000821

Lifting bolt

Chain sling with shortener xx1000001242

Lifting of robot xx0900000822

Oil

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

xx0900000823

Mechanical stop xx0900000824


46




1 Safety


Continued

Description

No mechanical stop

Symbol xx1000001144 xx0900000825

Stored energy

Warns that this part contains stored energy.

Used in combination with Do not disassemble symbol.

Pressure

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

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827

Do not step

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

xx1400002648




47


2 Installation and commissioning

2.1 Introduction


2.1 Introduction

General

This chapter contains assembly instructions and information for installing the IRB

6660 at the working site.

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

6660, such as:

• Load diagram

• Permitted extra loads (equipment), if any

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


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

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

Safety on page 19

before performing any installation work.

Note

If the IRB 6660 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work.

For more information see:





49


2.2.1 Pre-installation procedure

2.2 Unpacking

2.2.1 Pre-installation procedure

Introduction

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

Prerequisites for installation personnel

Installation personnel working with an ABB product must:

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

• conform to all national and local codes.

Checking the pre-requisites for installation

1

2

3

Action

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

Remove the packaging.

Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damages are found.

4

5

6

7

8

9

10

11

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

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

Weight, robot on page 50

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

Storage conditions, robot on page 53

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

Operating conditions, robot on page 53

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

•

Loads on foundation, robot on page 51

•

Protection classes, robot on page 53

•

Requirements, foundation on page 52

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

Risk of tipping/stability on page 58

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

On-site installation on page 60

Install required equipment, if any.

•

Signal lamp (option) on page 99

Weight, robot

The table shows the weight of the robot.

Robot model

IRB 6660

Weight

1950 kg


50






Continued

Note

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

Loads on foundation, robot

The illustration shows the directions of the robots stress forces.

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

T xy

F z

F xy

T z xx1100000521

F xy

F z

T xy

T z

Force in any direction in the XY plane

Force in the Z plane

Bending torque in any direction in the XY plane

Bending torque in the Z plane

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

Note

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

WARNING

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





51



Continued

Floor mounted

Force

Force xy

Force z

Torque xy

Torque z

Endurance load (in operation)

± 7.6 kN (IRB 6660 - 100/3.3)

± 8.5 kN (IRB 6660 - 130/3.1)

± 7.9 kN (IRB 6660 - 205/1.9)

18.5 ± 3.7 kN (IRB 6660 - 100/3.3)

18.8 ± 8.4 kN (IRB 6660 - 130/3.1)

18.0 ± 4.4 kN (IRB 6660 - 205/1.9)

± 24.4 kNm (IRB 6660 - 100/3.3)

± 25.6 kNm (IRB 6660 - 130/3.1)

± 19.6 kNm (IRB 6660 - 205/1.9)

± 7.6 kNm (IRB 6660 - 100/3.3)

± 10.3 kNm (IRB 6660 - 130/3.1)

± 7.1 kNm (IRB 6660 - 205/1.9)

Max. load (emergency stop)

± 12.8 kN (IRB 6660 - 100/3.3)

± 16.1 kN (IRB 6660 - 130/3.1)

± 14.9 kN (IRB 6660 - 205/1.9)

18.5 ± 7.4 kN (IRB 6660 - 100/3.3)

18.8 ±12.8 kN (IRB 6660 - 130/3.1)

18.0 ±7.7 kN (IRB 6660 - 205/1.9)

± 33.4 kNm (IRB 6660 - 100/3.3)

± 37.2 kNm (IRB 6660 - 130/3.1)

± 32.4 kNm (IRB 6660 - 205/1.9)

± 14.5 kNm (IRB 6660 - 100/3.3)

± 19.3 kNm (IRB 6660 - 130/3.1)

± 14.7 kNm (IRB 6660 - 205/1.9)

Requirements, foundation

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

Requirement

Flatness of foundation surface

Maximum tilt

Minimum resonance frequency

Value

0.3 mm

Note

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

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

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

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

5°

22 Hz

Note

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

The value is recommended for optimal performance.

Due to foundation stiffness, consider robot mass including equipment.

i

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

i

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

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


52






Continued

Storage conditions, robot

The table shows the allowed storage conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient temperature (less than 24 hrs)

Maximum ambient humidity

Value

-25° C

+55° C

+70° C

95% at constant temperature

(gaseous only)

Operating conditions, robot

The table shows the allowed operating conditions for the robot:

Parameter

Minimum ambient temperature

Value

+5° C

+50° C i

Maximum ambient temperature i

Maximum ambient humidity 95% at constant temperature

In a high speed presstending application, max ambient temperature is +40° C.

Protection classes, robot

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

Protection type

Manipulator, protection type Standard

Manipulator, protection type Foundry Plus

Protection class

IP 67

IP 67




53


2.2.2 Working range and type of motion

2.2.2 Working range and type of motion

Working range

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

IRB 6660 - 100/3.3

1211 (A)

1131 (B)

997

1755,5 200

B

G

A

2834

1125

C

F

D

300

645

E

940

3343 xx1200000979

(A)

(B)

(C)

Mechanical stop

Max. working range

Max. working range

Positions at wrist center

E

F

C

D

G

A

B

Position number, see figure above

X position (mm) Z position (mm) Axis 2 angle (degrees)

Axis 3 angle (degrees)

2055.5

997

1125

645

940

3343

2834

2374,5

2629

1189

-23

-734

742

2501

0

-42

-42

50

85

85

50

0

-20

28

120

120

15

-20







Continued

IRB 6660 - 130/3.1

1211 (A)

1131 (B)

Z

763

B

1619

1505.5 200

A

2596

904

C

G

F

D

X

300

770

1065

E

3102

1575 xx1000000662

(A)

(B)

(C)

Max. working range

Mechanical stop

Max. working range


C

D

E

F

G

A

B




1805.5

763

904

770

1065

3102

2596

2374.5

2544

1306

194

-518

807

2415

0

-42

-42

50

85

85

50

0

-20

28

120

120

15

-20





55



Continued

IRB 6660 - 205/1.9

xx1000000663

(A)

(B)

Max. working range

Max. working range


H

K

F

G

C

D

E

A

B




1193

575

751.5

632.2

793.3

1932.4

1579.6

1043.4

997.3

1794.5

1903.2

1162.7

351.1

-37.9

914.8

1833

2083.2

-60.4

0

-42

-42

50

85

85

50

0

85

0

-20

28

120

120

15

-20

-20

107.4







Continued

Type of motion

Axis

1

2

4

5

3

2-3

6

Type of motion

Rotation motion

Arm motion

Arm motion

Arm motion

Wrist motion

Bend motion

Turn motion

Range of movement

+180° to -180°

+85° to -42°

+120° to -20°

+20° to +160°

+300° to -300°

+120° to -120°

+300° to -300°

Note

Turning radius

B

A xx1200000980

Robot variant

IRB 6660 - 100/3.3

IRB 6660 - 130/3.1

IRB 6660 - 205/1.9



Radius A (axis-3 motor)

710 mm

710 mm

710 mm


Radius B

3343 mm

3102 mm

1932 mm

57


2.2.3 Risk of tipping/stability

2.2.3 Risk of tipping/stability

Risk of tipping

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

The shipping position is the most stable position.

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

Shipping and transportation position

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

42°

28° xx0700000001

A

B

IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

IRB 6660 - 205/1.9


58





2.2.3 Risk of tipping/stability

Continued

WARNING

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




59


2.3.1 Lifting robot with fork lift

2.3 On-site installation

2.3.1 Lifting robot with fork lift

General

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

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

Attachment points on robot

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

xx0500002276

A

B

C

Attachment points on adapter and horizontal attachment screws

Attachment points, horizontal attachment screws

Attachment points, vertical attachment screws

Required equipment

Equipment, etc.

Art. no.

Fork lift set, incl. all required hardware

3HAC023044-001

Note

See figure

Fork lift set, 3HAC023044-001 on page 61 .

Standard toolkit Content is defined in section

Standard tools on page 381

.







Continued

Fork lift set, 3HAC023044-001

The fork lift set 3HAC023044-001, is fitted to the robot as shown in the figure below.

xx0500002277

C

D

A

B

E

Fork lift pocket (2 pcs, one long and one short)

Adapter (2 pcs)

Horizontal attachment screws (4 pcs / fork lift pocket)

Attachment screw for adapter (1 pc / adapter)

Vertical attachment screws (2 pcs)





61



Continued

Lifting robot with fork lift

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

1

2

Action

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

Note

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

Release the brakes if required as detailed in section

Manually releasing the brakes on page 73

.

3 xx0700000517

Fit the two adapters to the robot and secure.

• A: IRB 6660 - 100/3.3, IRB 6660

- 130/3.1

• B: IRB 6660 - 205/1.9

Attachment points are shown in figure

Attachment points on robot on page 60 .

Attachment screws, 2 pcs, M16 x 90.

Tightening torque: 270 Nm.


62






Continued

4

Action

Strap up axis 2 motor cable on the adapter.

Note xx0500002278

• A: Strap, velcro

5

CAUTION

The fork lift pocket weighs 60 kg!

6 Secure the longer fork lift pocket to the adapter and frame with four of the horizontal attachment screws and washers .

Note

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

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

Attachment points on the robot are shown in figure


xx0500002279

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

60 Nm.

B Adapter





63



Continued

7

Action

Make sure the securing screw is removed from the fork lift pocket! It is only used for robot model IRB 6650S.

Note

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

Note

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

xx0700000655

A Securing screw xx0500002284

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

270 Nm.


Attachment points on robot are shown in figure


9

CAUTION

The fork lift pocket weighs 22 kg!

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

4 pcs, M16x60.



Attachment points on robot are shown in figure


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







Continued

Action Note

12

CAUTION Note

The IRB 6660 robot weighs 1950 kg.

All lifting accessories used must be sized accordingly!

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

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

14

WARNING

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

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




65


2.3.2 Lifting robot with roundslings

2.3.2 Lifting robot with roundslings

General

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

Sling specification

Sling type

Roundsling, robot

Qty

3 pcs

Lifting capacity

3 000 kg

Length / Note

2 m

Lifting with roundslings

1

2

Action

Position robot in a secure transport position.

Note

Attach roundslings to robot according to figure

Attachment points on page 66 .

3

Note

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

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

Shown in the figure

Attachment points on page 66

.

5

CAUTION Note




6

WARNING


Attachment points

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


66






Continued

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

IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

xx0700000002

A

B

C

Roundsling 2 m

Roundsling 2 m

Roundsling 2 m





67



Continued

IRB 6660 - 205/1.9

xx0700000426

A

B

C

Roundsling 2 m

Roundsling 2 m

Roundsling 2 m

68





2.3.3 Lifting robot with lifting slings

2.3.3 Lifting robot with lifting slings

General

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

Note

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

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





69



Continued

Illustration, lifting slings

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

IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

xx0700000004

D

E

F

I

L

A

B

C

Load hook

Swivelling lifting eyes, 4 pcs

Shortening hook

Chain

Lifting eye, M12

Eye for lifting accessory

Lifting slings, 4 pcs

Hook


70




IRB 6660 - 205/1.9



Continued xx0700000427

C

D

E

A

B

F

J

L

Load hook

Swivelling lifting eyes, 4 pcs

Shortening hook

Chain

Lifting eye, M12

Eye for lifting accessory

Lifting slings, 4 pcs

Hook





71



Continued


Equipment

Lifting accessory, robot

Article number

3HAC15607-1

Note

Includes user instructions 3HAC15971-2

Slings attached directly onto robot

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

1

2

3

Action

Run the overhead crane to a position above the robot.

Note

Position the robot as detailed in enclosed instruction!

Article number is specified in

Required equipment on page 72 .

Release the brakes, if required, as detailed in section


Note

Shown in the figure

Illustration, lifting slings on page 70 .

If the robot is equipped with forklift pockets, it is necessary to remove these in order to reach the lower holes in the frame. These are used to attach the hooks of the lifting slings.

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

5

CAUTION


equipment on page 72 .

Required

Note




6

WARNING


7 Raise overhead crane to lift the robot.

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

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

72





2.3.4 Manually releasing the brakes

2.3.4 Manually releasing the brakes

Introduction to manually releasing the brakes

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

Location of brake release unit

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

xx0700000005

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 74

.

Buttons are shown in figure

Location of brake release unit on page 73 .

2

DANGER

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

Make sure no personnel is near or beneath the robot.

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

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




73



2.3.4 Manually releasing the brakes

Continued

Supplying power to connector R1.MP

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

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

Action Note

1

DANGER

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

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

xx0600002937

74





2.3.5 Lifting the base plate

2.3.5 Lifting the base plate


Equipment

Lifting eye, M16

Lifting slings

Hole configuration

Article number

3HAC14457-4

Note

3 pcs

Length: approx. 2 m xx0200000096

A Attachment holes for lifting eyes (x3)

Lifting, base plate

Action Note

1

2

3

CAUTION

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

Fit lifting eyes in specified holes.

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

Shown in figure

Hole configuration on page 75

.

CAUTION

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





2.3.6 Securing the base plate

2.3.6 Securing the base plate

Base plate, dimensions

D G

F

B

B

H

2x R525

598,31

560,85

487,01

(Ø 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)


76







A Four holes for alternative clamping, 4x Ø18





77



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)


78






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

3HAC12937-7 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 381 .

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




79




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 78 .

Detailed in section

on page 75 .

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 78 .

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.

80





2.3.7 Orienting and securing the robot

2.3.7 Orienting and securing the robot

General

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

Illustration, robot fitted to base plate

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

xx0100000107

A

B

C

D

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

Orienting grooves in the robot base and in the base plate

Levelling screws

Base plate attachment screws

Attachment screws

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

Suitable screws, lightly lubricated:

Quality:

Suitable washer:

Tightening torque:

M24 x 140

Quality 8.8

Thickness: 4 mm

Outer diameter: 44 mm

Inner diameter: 25 mm

725 Nm





81



Continued

Securing the robot

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

1

2

3

Action

Lift the robot.

Note

See section

Lifting robot with lifting slings on page 69 .

See section

Lifting robot with roundslings on page 66 .

Move robot to the vicinity of its installation location.

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

Shown in figure

Base plate, guide sleeve holes on page 79 .

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 81 .

Shown in figure

Illustration, robot fitted to base plate on page 81 .

Note

Lightly lubricate screws before assembly!

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


82






Continued

Hole configuration, base

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

xx0300000046

Cross section, guide sleeve hole

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

xx0100000109




83


2.3.8 Fitting equipment on robot

2.3.8 Fitting equipment on robot

General

The robot features mounting holes for additional equipment.

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

Note

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

Note

No extra equipment may be fitted on the lower arm of the robot.

Illustration, fitting of extra equipment on upper arm

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

xx0700000015

Number

1

2

Robot variant

IRB 6660 - 100/3.3

IRB 6660 - 130/3.1

IRB 6660 - 205/1.9

A

1747.5 mm

1497.5 mm

885 mm

B

190 mm

190 mm

190 mm

C

490 mm

490 mm

490 mm

D

128 mm

128 mm

128 mm







Continued xx0700000014 xx0700000674





85



Continued

Illustration, fitting of extra equipment on frame

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

Illustrations show robot variant IRB 6660 - 130/3.1 but all shown measurements are the same on all variants.

xx0700000013 xx0700000012


86






Continued

Illustration, fitting on turning disc

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

xx0200000197

Turning disk (type 2) for all robot versions.

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 on the upper arm house or frame.





2.3.9 Installation of chip protection - IRB 6660 - 205/1.9

2.3.9 Installation of chip protection - IRB 6660 - 205/1.9

Note

This section is only applicable to the robot variant IRB 6660 - 205/1.9.

Location of chip protection

The chip protection is installed on the lower arm as shown in the figure below.

xx0700000630

A

B

C

D

Bracket

Attachment screws M6x16 quality 8.8-A2F (2 pcs per side)

Attachment screws M6x16 quality 8.8-A2F (4 pcs)

Protection


Equipment

Chip protection

Locking liquid -

Art. no.

3HAC030124-001

Note

Standard toolkit

Loctite 243

For locking screws.






88





2.3.9 Installation of chip protection - IRB 6660 - 205/1.9

Continued

Installation, chip protection

The procedure below details how to install the chip protection on the lower arm of the robot.

Action Note

1

DANGER

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

2

3

4

Place the chip protection around the lower arm.

As shown in the figure

Location of chip protection on page 88

.

Fit the bracket on the chip protection with its attachment screws - two screws on each side of the lower arm.

Lock screws with locking liquid .

Art. no. is detailed in


Let the protection hang down in front of the lower arm and base of the robot.

As shown in the figure

Location of chip protection on page 88

.




89


2.3.10 Installation of cooling fan for motors (option)

2.3.10 Installation of cooling fan for motors (option)

General

A cooling fan can be installed on motor axis 1 and/or axis 2!

Location of cooling fans

The fan can be installed on motor axis 1 and/or axis 2, as shown in the figure below.

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

xx1800000169

A

B

Cooling fan, axis 1

Cooling fan, axis 2 xx1800000170


90




Cooling fan



Continued

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

xx0500002158

A

B

C

D

Fanbox

Attachment screws, fanbox plates (9 pcs)

Groove in the connector

Tightening screws, fanbox (3 pcs)


Equipment Article number

Cooling fan 3HAC15374-1

Cabling, cooling fan, axes 1 and 2

3HAC046362-001

Plate for customer connections

3HAC025778-001

Note

Additional cabling to the controller

-

Material set fan axes 1 and

2

3HAC023999-001

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

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

Plate for customer connections, at base on page 92

.

Specified in section

Fan cables (option) on page 106 .

The set includes:

• fan axes 1 & 2 cable harness

• plate, customer

• attachment screws and nuts.

Cable harness inside controller

3HAC025488-001




91




Continued

Equipment

Locking liquid

Standard toolkit

-

-

Article number

Circuit diagram

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

3HAC025744-001

Note

Loctite 243. Used for the three tightening screws.



.

See chapter



Plate for customer connections, at base xx0500002301

A

B

Plate for customer connections

Attachment screws, 3 pcs, M6x16 quality 8.8-A2F


92






Continued

Installation, fan

.

The procedure below details how to install the cooling fan on motors, axes 1 or 2

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 Prepare the fanbox for installation:

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

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

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

Cooling fan on page 91

.

Shown in the figure

Cooling fan on page 91

.

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

4

5

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

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

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





93



Continued

Separate cabling for axis 1 or 2

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

xx0700000669

A

B

C

Cable bracket (to be removed)

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

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

Installation, separate fan cabling axis 1 or 2

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

1

Action

Move the robot to its calibration position.

Note

This is detailed in section

Synchronization marks and synchronization position for axes on page 345

.

2

DANGER

Turn off all:






94






Continued

3

Action

Remove the rear cover plate from the robot base.

Note

4

5 xx1800000161

Remove the cable bracket (A) Shown in the figure

Separate cabling for axis 1 or 2 on page 94

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

Art. no. is specified in

Required equipment on page 91

.

xx1800000162

6

7

Run the cabling up through the base and frame.

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

1 or 2.

Strap the fan cable to the cable of the motor axis

1 or 2, close to the motor.

Note

The fan cable must not be strapped to the motor cable along the part of the cable that is twisted when the robot is in operation.

8

9

10

11

Connect the connector R3.FAN2 to the fan of axis

1.

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

Refit the rear cover plate to the robot base.

Install additional cabling to and inside the controller.

Cable is specified in section


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





95



Continued

Adjustments in RobotWare

1

Action

Modify the settings in RobotWare to include the cooling fans.

Note

RobotWare 5.0: change the settings in the

Modifying options dialogue, by using the

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

RobotStudio .

96





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

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

Introduction

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

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




97


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

2.3.12 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.

98





2.3.13 Signal lamp (option)

2.3.13 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.




99


2.4.1 Axes with restricted working range

2.4 Restricting the working range

2.4.1 Axes with restricted working range

General

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

The working range of the following axes may be restricted:

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

• Axis 2, software.

• Axis 3, software.

As standard configuration, axis 1 is allowed to move ± 180º.

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.

100





2.4.2 Mechanically restricting the working range of axis 1

2.4.2 Mechanically restricting the working range of axis 1

General

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

Mechanical stops, axis 1

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

xx0300000049

A

B

Additional mechanical stop

Stop pin


Equipment, etc.

Mechanical stop for axis 1, 7.5°

Mechanical stop for axis 1, 15°

Standard toolkit

Technical reference manual - System parameters

-

-

Article number

3HAC11076-1

3HAC11076-2

Note

Includes attachment screws and an assembly drawing.

Includes attachment screws and an assembly drawing.

Article number is specified in section

References on page 10 .




101



2.4.2 Mechanically restricting the working range of axis 1

Continued

Installation, mechanical stops axis 1

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

Action Note

1

DANGER

Turn off all:





2

3

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

Mechanical stops, axis 1 on page 101

.


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.

102





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

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

Overview

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

220º.

Extending the working range

1

Action

Remove the mechanical stop pin from axis

1 (A).

Note/Illustration xx0400001034

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

Motion . The Arm parameters Upper Joint

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

= 220 degrees.

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




103


2.5.1 Robot cabling and connection points

2.5 Electrical connections

2.5.1 Robot cabling and connection points

Introduction

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

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

Main cable categories

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

Cable category

Robot cables

Fan cables (option)

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 104 .

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

Specified in the table


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

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

Connection point, cabinet

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

XS1

XS2

Connection point, robot

R1.MP

R1.SMB

Robot cable, power

Cable

Robot cable, power: 7 m





104

Art. no.

3HAC026787-001

3HAC026787-002

3HAC026787-003

3HAC026787-004






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.

xx1600001000





105



Continued

Fan cables (option)

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

Cabling to be installed on the robot is specified in section

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

.

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

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

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

Cable

Harness - cooling, 7 m

Art. no.

3HAC022723-001

Harness - cooling, 15 m 3HAC022723-004



Connection point

Distributing cable: R1.FAN.SW2/3

Inside cabinet: A43.X10 and A43.X11







106





2.6 Start of robot in cold environments

2.6 Start of robot in cold environments

Introduction

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

Problems with starting the robot

Event message from Motion Supervision

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

1

2

3

Action

Turn off Motion Supervision.

Start the robot.

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

Note

Robot stopping with other event message

Use this procedure if the robot is not starting.

1

Action

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

Note

The speed can be regulated with the

RAPID instruction VelSet .

Adjusting the speed and acceleration during warm-up

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

Work cycles

3 Work cycles

5 Work cycles

5 Work cycles

5 Work cycles

More than 5 Work cycles

AccSet

20, 20

40, 40

60, 60

100, 100

100, 100

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

Max.

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





3 Maintenance

3.1 Introduction

3 Maintenance


Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB

6660.

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 19

before performing any service work.

Note

If the IRB 6660 is connected to power, always make sure that the IRB 6660 is connected to protective earth before starting any maintenance work.






109

3 Maintenance

3.2.1 Specification of maintenance intervals

3.2 Maintenance schedule and 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 6660:

• 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.

110




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 113

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

•

Inspection activities on page 114

•

Replacement/changing activities on page 144

•

Cleaning activities on page 169

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

Inspection

Change

Equipment

Robot

Oil level in axis-1 gearbox






Balancing device

Robot harness

Information labels

Dampers

Mechanical stop

Oil in axis-1 gearbox

Change Oil in axis-2 gearbox

Interval

Cleaning the IRB 6660 on page 169

Every 12 months.

Every 12 months.

Every 12 months.

Every 12 months.

Every 12 months.

Every 12 months.

Every 6 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

• 24,000 hours

ii

reads:

Following changes:

• Every 24,000 hours.


• 6,000 hours

• 24,000 hours ii reads:


ii

reads:

Following changes:





111


3 Maintenance

3.2.2 Maintenance schedule

Continued

Maintenance activity

Change

Change

Equipment



Interval


ii

• 6,000 hours reads:


ii

• 24,000 hours reads:

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

Replacement

Robot Every:

• 40,000 hours iii

.

Battery pack, measurement system of type RMU101 or

RMU102 (3-pole battery contact)

36 months or battery low alert iv

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

Battery low alert v

Lubrication Balancing device bearings Every 12,000 hours vi i

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

Expected component life on page 113 .

ii

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

iii

If the robot is run in presstending applications, typically 36 months.

iv The battery low alert (38213

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

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

See the replacement instruction for more details.

v

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

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

FlexPendant for instructions.

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

Activities and intervals, optional equipment

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

Note Maintenance activity

Inspection

Inspection

Inspection

Equipment

Signal lamp

Interval

Every:

12 months

Additional mechanical stop axis 1

Every:

12 months

Motor fan Every 12 months

Inspect the fan for contamination that could hinder the air supply. Clean if necessary.




3 Maintenance

3.2.3 Expected component life

3.2.3 Expected component life

General

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

Expected component life - protection type Standard

Component

Cable harness

Normal usage i

Expected life

40,000 hours ii

Note

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Cable harness

Extreme usage iii

20,000 hours

ii

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Balancing device

Gearboxes v

40,000 hours

40,000 hours iv i

Examples of "normal usage" in regard to movement: most material handling applications.

ii

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

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

v

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

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 .




113

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.

D

C

A

B

E xx0500002479

A

B

C

D

E

Oil plug, inspection

Gearbox, axis 1

Oil plug filling

Motor, axis 1

Drain hose (Behind cover)


Equipment

Lubricating oil

Standard toolkit -

Art. no.

See

Type and amount of oil in gearboxes on page 144 .

Note

Note

Do not mix with other oils!







3 Maintenance


Continued

Equipment


Art. no.

Note


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 38

.

2

3

4

5

DANGER

Turn off all:

• electric power supply

• hydraulic pressure supply

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

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

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

Open the oil plug, inspection .

Measure the oil level.

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

Shown in figure

Location of gearbox on page 114 .

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 144 .

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

Changing oil, axis-1 gearbox on page 146 .

Tightening torque:24 Nm

115

3 Maintenance

3.3.2 Inspecting, oil level gearbox axes 2 - 3

3.3.2 Inspecting, oil level gearbox axes 2 - 3

Location of gearbox, axes 2-3

The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor attachment.

xx0500002482

C

D

A

B

Gearbox, axis 2

Oil plug, draining

Oil plug, filling

Ventilation hole, gearbox axis 2


116




3 Maintenance



A

B

C

D

Gearbox, axis 3

Oil plug, draining

Oil plug, filling

Ventilation hole, gearbox axis 3


Equipment etc.

Lubricating oil

Standard toolkit

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

-

Art.no.

See


Note

Note




.


Inspecting, oil level gearbox 2 - 3

Use this procedure to inspect the oil level in gearbox axes 2 - 3.

Action Note

1

WARNING




.





117

3 Maintenance


Continued

Action Note

2

3

4

5

6

DANGER

Turn off all:





Open oil plug, filling See

Location of gearbox, axes 2-3 on page 116

.

Measure oil level at the oil plug, filling.

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

Add oil if required.

Art.no. is specified in


Filling of oil is detailed further in section

Changing oil, gearbox axes

2 and 3 on page 149 .

Refit oil plug, filling.


118




3 Maintenance




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

xx0700000018

A

B

Oil plug, filling and inspection

Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit


-

Art. no.

See


Note



.






119

3 Maintenance


Continued



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 38 .

2 Move the robot to the calibration position.



.

3

4

5

6

DANGER

Turn off all:





Make sure that the oil temperature is +25°C

±10°C.

Open the oil plug, filling and inspection

Measure the oil level.

Required oil level: 0-10 mm

.


Shown in the figure

Location of gearbox on page 119

.

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 154

.


120




3 Maintenance




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

xx0200000232

-

A

B

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

Oil plug, filling and inspection

Oil plug, draining


Equipment etc.

Lubricating oil

-

Art. no.

See


.

Note

Standard toolkit







Action Note

1

WARNING







121


3 Maintenance


Continued

2

3

Action

Move the robot upper arm to a horizontal position.

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

Note

4

DANGER

Turn off all:





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

±10°C.

6 Open the oil plug, filling and inspection .


Shown in the figure


7 Measure the oil level.

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



xx0500002222




Filling, oil, axis 5 on page 157 .


122




3 Maintenance




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

The figure shows the gearbox for robot variant IRB 6660 - 100/3.3 and IRB 6660 -

130/3.1. The axis-6 motor on variant IRB 6660 - 205/1.9 has no cooling elements.

xx0700000161

A

B

C

D

E

Strap (securing cooling elements)

Axis-6 gearbox

Oil plug, draining

Oil plug, filling

Cooling element (IRB 6660 - 100/3.3 and IRB 6660 - 130/3.1)


Equipment

Lubricating oil

Standard toolkit -

Art. no.

See


Note









123

3 Maintenance


Continued



Action Note

1

WARNING



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

3

DANGER

Turn off all:





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

±10°C.


5 Remove the oil plug, filling and inspection .

xx1300002447

6

7

Slowly turn axis 4 until the axis-4 angle reads

+72.5° to +77.5°.

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

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

C

A

B

Note

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

xx1400002786

A Oil plug hole


C Gearbox oil





3 Maintenance


Continued

8

Action

Adjust the oil level, if required.

9

10

Refit the oil plug.

WARNING

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



.


Filling, oil, axis 6 on page 160 .





125

3 Maintenance

3.3.6 Inspecting, balancing device bearings and piston rod guide ring

3.3.6 Inspecting, balancing device bearings and piston rod guide ring

Note

This section is not applicable to robot variant IRB 6660-205/1.9.

Location of balancing device

The figure shows the location of the balancing device.

xx0700000019

A

B

C

Balancing device

Piston rod

Guide ring (not visible in this figure)


Equipment

Grease

Locking liquid

Auxiliary shaft, upper

Auxiliary shaft, lower

Standard toolkit

Art.no

-

3HAB3537-1

-

3HAC5276-1

3HAC5275-1

Note

Loctite 243







3 Maintenance


Continued

Equipment


Art.no

Note


Inspecting, bearings

Use this procedure to inspect the bearings, balancing device.

1

2

Action

Move axis 2 to calibration position.

Note

DANGER

Turn off all:





3 Remove locknuts (KM10), sealing rings and support washers.

4 Fit the auxiliary shafts on upper and lower axes of balancing device.

The shafts should be tightened to their bottom position.

xx0500002496

A Ear (adjustable needle bearing located inside)

B Support washer

C Lock nut KM10 (with sealing ring)

D Piston rod

E Guide ring (not visible in this view)

F Inner ring



.




127


3 Maintenance


Continued

5

Action

Remove the protection hood from the

M12 hole on top of the balancing device.

Note

6

7

8 xx0600002687

A Attachment (seen from above)

B Protection hood

Unload the bearings using a M12x50 screw, in the hole for the protective hood, at the cylinder top.

Pull out the cylinder a little, in order to be able to inspect the inner rings without removing the balancing cylinder.

Shown in previous figure in this procedure.

Wipe the inner rings clean and check that there are no pressure marks or other similar deformations.

Note

It is quite normal for the bearing races to have a darker color than the surrounding material.

9

10

11

12

Inspect the bearings , support washers and sealing rings .

If any of the parts looks abnormal, replace.

Lubricate the shafts, if needed.

Push the cylinder back in.

Shown in previous figure.

Detailed in section

Replacing the balancing device on page 266

.

Make sure that the inner support washers and sealing rings get in the correct position.

13

14

Remove the auxiliary shafts.

Remove the M12x50 screw.

Put back the protection hood in the hole.

Note

Don´t forget to remove the screw!

If the screw isn´t removed it may damage the balancing device, when the robot starts operating.

15 Apply locking liquid on the lock nuts

(KM10) and refit them.

Tightening torque on the lock nuts:

• 120 Nm


128




3 Maintenance


Continued

Inspecting, piston rod guide ring

Use this procedure to inspect the piston rod guide ring for wear.

1

Action

Move axis 2 to a position where the balancing device is in a horizontal position.

Note

2

DANGER

Turn off all:





3 Check the guide ring for wear.

Replace if necessary.

4

Note

If there is a risk of metallic contact between the piston rod and the end cover, the guide ring must be replaced!

xx0600002689

A Guide ring

B Circlip




129

3 Maintenance

3.3.7 Inspection, cable harness

3.3.7 Inspection, cable harness

Location of cable harness

The robot cable harness, axes 1-6 is located as shown in the figures below: xx0700000022

A

B

C

D

E

Cable guide, axis 2

Metal clamp (4 pcs)

Connectors at base

Cable guide

Cable harness


130




xx0700000631

A

B

C

Cable guide, axis 1

Cable gland, SMB unit

Cable guide, axis 2

3 Maintenance


Continued





131

3 Maintenance



A

B

C

D

E

Cable strap, outdoor

Attachment screw, M10x16 quality 8.8 (2 pcs)


Cable fixing bracket

Attachment screw, metal clamp M6x25 quality steel 12.9 Gleitmo


Equipment, etc.

Cable harness

Standard toolkit


Circuit diagram -

-

Art. no.

For spare part number, see

Spare part lists on page 387 .

Note




See chapter

on page 389

.

Circuit diagram





3 Maintenance


Continued

Inspection, cable harness

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

Action Note

1

DANGER


2

3

4

5

6

7

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

Check the connectors at the base.

Shown in the figure

Location of cable harness on page 130 .

Check the metal clamps at the rear of the upper arm and in the upper arm tube.

Shown in the figure

Location of cable harness on page 130 .

Check that the velcro straps and the mounting plate are properly attached to the frame.

Check the cabling leading into the lower arm.

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

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

Detailed in sections

Replacement of cable harness, lower end (axes

1-3) on page 181

and


.




133

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 42 .

xx0700000047

-

E

F

A

B

C

Warning label concerning high temperature (2 pcs)

Warning label, symbol of flash (located on motor cover) (2 pcs)

Instruction label

Instruction label concerning lifting the robot

Warning label concerning risk of tipping

Information labels at gearboxes and at robot base, specifying which oil is used in gearboxes.


134




3 Maintenance

3.3.8 Inspecting the information labels


D

G

H

A

B

K

L

I

J

Warning label concerning high temperature (2 pcs)

Warning label, symbol of a flash (located on motor cover) (1 pcs)

Warning label concerning brake release

Serial no. from rating label

Warning label concerning stored energy

Label calibration

Warning label concerning shutting off power

Abs-Acc information sign

Danger label concerning clamping risk

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




135


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.

Location of mechanical stop pin

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

xx0200000151

A Mechanical stop pin


Visual inspection, no tools are required.

Inspecting, mechanical stop pin

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

Action Note

1

DANGER

Turn off all:





136




3 Maintenance

3.3.9 Inspecting the axis-1 mechanical stop pin

Continued

2

Action

Inspect the axis-1 mechanical stop pin.

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

Note

Note

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

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




137

3 Maintenance

3.3.10 Inspecting the additional mechanical stops

3.3.10 Inspecting the additional mechanical stops

Location of mechanical stops

This figure shows the location of the additional mechanical stop on axis 1.

Additional mechanical stops are not provided for axis 2 and 3.

xx0300000049

A

B

Additional mechanical stop

Stop pin


Equipment etc.

Mechanical stop axis 1

Mechanical stop axis 1

Standard toolkit -

Article number

3HAC11076-1

3HAC11076-2

Note

Limits the robot working range by 7.5°.

Limits the robot working range by 15°.



.


138




3 Maintenance

3.3.10 Inspecting the additional mechanical stops

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 138 .

Make sure the stops are properly attached.

Correct tightening torque, additional mechanical stops:

• Axis 1 = 120 Nm.

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

Correct attachment screws:

• Axis 1: M16 x 35, quality 12.9.






139

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.

The figure shows the robot variant IRB 6660 - 130/3.1. Dampers and the position of the dampers are the same on all variants.

xx0700000024

A

B

C

D

E

F

Damper (2 pcs)

Damper, axis 2 (2 pcs)

Damper, axis 3 (2 pcs). Not visible in this view.

Damper (1 pcs)

Damper, axis 4 (1 pcs), inside armhouse

Damper, axis 5 (2 pcs)


A damper must be replaced if damaged!

Equipment

Damper axis 2

Damper

Damper

Standard toolkit

Spare part/ art. no.

3HAC12991-1

3HAC022338-001

3HAC022339-001

3HAC15571-1

Note







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.

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

Shown in the figure

Location of dampers on page 140 .

Check attachment screws for deformation.

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



.




141

3 Maintenance

3.3.12 Inspecting, signal lamp (option)

3.3.12 Inspecting, signal lamp (option)

Location of signal lamp

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

xx0700000056

A

B

C

Signal lamp

Metal clamp



Equipment, etc.

Signal lamp

Standard toolkit


-

Art. no.

3HAC028196-001

Note

To be replaced in case of detected damage.



.


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


142




3 Maintenance

3.3.12 Inspecting, signal lamp (option)

Continued

Action

2

DANGER

Turn off all:





Note

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.



.




143

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.

xx0700000026

A Gearbox, axis 1


144




Equipment

3 Maintenance

3.4.1 Type of lubrication in gearboxes

Continued

B

C

D

E

F

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 4

Gearbox, axis 5

Gearbox, axis 6

Equipment

Oil dispenser

Nipple for quick connect fitting, with o-ring

Note

Includes pump with outlet pipe.

Use the suggested dispenser or a similar one:

• Orion OriCan article number 22590

(pneumatic)




145

3 Maintenance

3.4.2 Changing oil, axis-1 gearbox

3.4.2 Changing oil, axis-1 gearbox

Location of oil plugs

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

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

D

C

A

B

E xx0500002479

C

D

E

A

B

Oil plug, inspection

Gearbox axis 1

Oil plug, filling

Motor, axis 1

Drain hose


Equipment, etc.

Lubricating oil

Art. no.

See


.

Amount Note

See


.

Note


Capacity: 8,000 ml.

Oil collecting vessel


146

-




3 Maintenance


Continued

Equipment, etc.

Oil exchange equipment

Standard toolkit -

Art. no.

3HAC021745-001

Amount Note


Special tools on page 382

.



Draining oil, axis-1 gearbox

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

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

Art. no. for the kit is specified in


Action Note

1

DANGER

Turn off all:




2

WARNING



3

4

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

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

5 Place an oil vessel close to hose end.

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

xx0200000237

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

A Oil draining hose

Vessel capacity is specified in


.

Shown in figure

Location of oil plugs on page 146 .





147

3 Maintenance


Continued

7

Action

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

Note

Note

CAUTION

Drain as much oil as possible. See


.

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

8

9

Close the oil drain hose, and put it back inside the base.

Refit rear cover by securing it with its attachment screws.

Filling oil, axis-1 gearbox

Use this procedure to fill gearbox axis 1 with oil.

Action

1

DANGER

Turn off all:




Note

2

WARNING




.

3

4

Open the oil plug, filling.

Shown in figure

Location of oil plugs on page 146

.

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.


148




3 Maintenance

3.4.3 Changing oil, gearbox axes 2 and 3

3.4.3 Changing oil, gearbox axes 2 and 3

Location of oil plugs

Gearboxes, axes 2 and 3, are located in lower arm rotational center, underneath motor attachment.

The figure shows the position of gearbox, axis 2.

xx0500002482

C

D

A

B

Gearbox axis 2

Oil plug, draining

Oil plug, filling

Ventilation hole plug, gearbox axis 2





149

3 Maintenance


Continued

The figure shows position of gearbox, axis 3.

xx0500002483

A

B

C

D

Gearbox, axis 3

Oil plug, draining

Oil plug, filling

Ventilation hole plug, gearbox axis 3


Equipment etc.

Lubricating oil

Art. no.

See


.



Standard toolkit -

3HAC021745-001

Amount Note

See


.

Note


Capacity: 6,000 ml


Special tools on page 382 .




150




3 Maintenance


Continued

Draining, axes 2 and 3

Use this procedure to drain oil in gearbox axes 2 and 3.

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

Action Note

1

DANGER

Turn off all:




2

WARNING



3

4

5

Remove the ventilation hole plug.

Shown in


.

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

Shown in


.



.

Draining is time-consuming.

Elapsed time varies depending on the temperature of the oil.

Refit the oil plug, draining.


Filling, axes 2 and 3

Use this procedure to fill gearboxes of axes 2 and 3 with oil.

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

Action Note

1

DANGER

Turn off all:








151

3 Maintenance


Continued

Action Note

2

3

WARNING



Remove the oil plug, filling . ( Ventilation hole plug should also be removed.)

Shown in



4

5

6

Note

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

Refill gearbox with lubricating oil .

The amount of oil to be filled depends on the amount that was previously drained.

Art.no. and total amount are specified in


.

Refit oil plug,filling and ventilation hole plug .

Shown in



152




3 Maintenance




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

xx0700000018

A

B

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See


.

Oil exchange equipment 3HAC021745-001


Standard toolkit

-

-

Amount

See


.

Note



.

Capacity: 9,000 ml.



.





153

3 Maintenance


Continued

Draining, oil

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

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


Note

1

Action

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

2

DANGER

Turn off all:





3

WARNING



4

5

6

7

Remove the oil plug, filling .

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).



.



Filling, oil

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



Action Note

1

DANGER

Turn off all:









3 Maintenance


Continued

Action Note

2

3

4

WARNING






.

Refit the oil plug, filling.

Shown in the figure


.







155

3 Maintenance




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

xx0200000232

-

A

B

Wrist unit of IRB 6600 and IRB 6650

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Art. no.

See


Oil exchange equipment 3HAC021745-001


Standard toolkit

-

-

Amount

See


Note


Special tools on page 382 .

Capacity: 7,000 ml.



Draining, oil, axis 5

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



Note

1

Action

Run axis 4 to a position where the oil plug for draining is facing downwards.


156




3 Maintenance


Continued

Action Note

2

DANGER

Turn off all:





3

4

5

6

WARNING




.

Remove the oil plug, filling .

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

Shown in the figure


.





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:









157

3 Maintenance


Continued

4

5

Action Note



Inspecting the oil level in axis-5 gearbox on page 121 .

Shown in the figure


.



Refit the oil plug, filling.


158




3 Maintenance




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

The figure shows the axis-6 gearbox for robot variant IRB 6660 - 100/3.3 and IRB

6660 - 130/3.1, and includes cooling elements on motor. There are no cooling elements on the axis-6 motor on robot variant IRB 6660 - 205/1.9.

xx0700000161

C

D

E

A

B

Strap

Gearbox, axis 6

Oil plug, draining

Oil plug, filling

Cooling elements (IRB 6660 - 100/3.3, IRB 6660 - 130/3.1)


Equipment, etc.

Lubricating oil

Art. no.

See



3HAC021745-001

Oil collecting vessel -

Standard toolkit -

Amount

See


.

Note

Note




.

Vessel capacity:

500 ml







159

3 Maintenance


Continued

Draining, oil, axis 6

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



1

Action

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

Note

Shown in the figure


2

DANGER

Turn off all:





3

WARNING




.

4

5

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

Measure the amount of oil drained.

Refit the oil plug, draining .



.

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


Filling, oil, axis 6

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



Action Note

1

DANGER

Turn off all:






160




3 Maintenance


Continued

Action Note

2

3

4

5

WARNING




.

Remove the oil plug, filling.

Shown in the figure


.




.



Refit the oil plug.

Inspect the oil level.


Detailed in the section

Inspecting the oil level in axis-6 gearbox on page 123 .




161

3 Maintenance

3.4.7 Replacing the SMB battery

3.4.7 Replacing the SMB battery

Note

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

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

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

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

WARNING

See instructions for batteries,

Safety risks during handling of batteries on page 37

.

Location of SMB battery

The SMB battery (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure.

Battery pack with a 2-pole battery contact (DSQC) xx0700000029

A

B

C

SMB battery cover

SMB battery pack with 2-pole battery contact.

Battery cable


162




Battery pack with a 3-pole battery contact (RMU)

3 Maintenance


Continued

A xx1400002574

E

F

G

A

B

C

D

B C

Battery pack RMU

Holder for battery

SMB cover

Battery cable

Battry holder

Guide pin (2 pcs)

SMB unit

D E F G


Note

There are two variants of SMB units and batteries. One with 2-pole battery contact

(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole battery contact has longer lifetime for the battery.

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

Equipment, etc.

Battery unit

Standard toolkit -

Spare part no.

For spare part no.

see:

•

Spare part lists on page 387

Note

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






163


3 Maintenance


Continued

Equipment, etc.

Circuit diagram -

Spare part no.

Note

See chapter

Circuit diagram on page 389

.

Removing, battery

Use this procedure to remove the SMB battery.

1

Action

Move the robot to its calibration position.

Note

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

2

DANGER

Turn off all:




3

ELECTROSTATIC DISCHARGE (ESD)

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

The unit is sensitive to ESD on page 33

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

Shown in figure

Location of SMB battery on page 162 .

CAUTION

Clean cover from metal residues before opening.

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

5

6

Pull out the battery and disconnect the battery cable .

Remove the SMB battery.

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

Shown in figure


Shown in figure


Refitting, battery

Use this procedure to refit the SMB battery.

Action

1

DANGER

Turn off all:





164


Note



3 Maintenance


Continued

Action Note

2

3


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


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



Note

Shown in figure

Location of SMB battery on page 162

.

C

RMU batteries are installed together with a battery holder to be properly secured inside the recess.

See figure.

Strap the battery cable to the holder.

4

5

A

D xx1300000307

A Battery pack RMU

B Battery holder

C Battery cable

D Strap

B

Secure the SMB battery cover with its attachment screws.

Shown in figure

Location of SMB battery on page 162

.

Update the revolution counters.

Detailed in chapter Calibration section

Updating revolution counters on page 348 .

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 28 .




165

3 Maintenance

3.5.1 Lubricating balancing device bearings and piston rod

3.5 Lubrication activities

3.5.1 Lubricating balancing device bearings and piston rod

Note

This section is not applicable to the robot variant IRB 6660-205/1.9

Overview

This procedure details how to lubricate bearings and piston rod of the balancing device.

Location of bearing and piston rod

This figure shows the location of bearings and piston rod.

Note!

Balancing device must be fitted on robot when lubricating bearings.

xx0500002489

A

B

Ear (bearing located inside)

Support washer


166




3 Maintenance


Continued

C

D

E

Lock nut

Piston rod

Guide ring (not visible in this view)


Equipment

Lubrication tool

Bearing grease

Cleaning agent

Piston rod grease

Locking liquid

Standard toolkit


-

-

-

-

Art.no.

3HAC5222-1

3HAB3537-1

Note

Equivalent:

• Shell Alvania WR 2

Isopropanol

Choose any of following equivalents:

• Shell: SRS Grease 4000

• Preem: Novatex Heavy EP 2

• Castrol: Entrepenadfett

• Statoil: Uniway 2X2N

Loctite 243




Lubricating, bearings

Use this procedure to lubricate the balancing device bearings.

1

2

Action

Move axis 2 to calibration position.

Note

DANGER

3

4

5

6

7

8

Turn off all:





Remove locknut.

Be careful not to loose the support washer in the process.

Fit the lubricating tool. It should be tightened to the bottom, by hand only.

Grease through nipple on the lubricating tool.

Continue filling grease until clean grease exudes behind the inner sealing ring.

Repeat this procedure at the other bearing!

Remove lubricating tool and clean threads on shaft ends free from grease.

Also clean from old grease on the inner side!

Apply some grease on the support washers.




167


3 Maintenance


Continued

9

Action

Apply locking liquid on the lock nuts (KM10).

Note

Tightening torque on lock nuts:

• 120 Nm

Note

Do not apply locking liquid on the shafts!

10 Check play between support washer and bearings at both bearings.

Minimum play:

• 0.1 mm

Lubricating, piston rod

Use this procedure to lubricate the balancing device piston rod.

1

Action

Move axis 2 to a position where the balancing device is in horizontal position and the piston rod extended as much as possible.

Note

2

DANGER

Turn off all:





3

4

Clean piston rod with isopropanol before applying new grease.

Apply new grease.

Type of grease is specified in

Required equipment on page167 .

168




3 Maintenance

3.6.1 Cleaning the IRB 6660

3.6 Cleaning activities

3.6.1 Cleaning the IRB 6660

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 6660 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 6660.

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 114 .

2 Write down the oil level.

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

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

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.

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

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

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

• Do not use compressed air to clean the robot.

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

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

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





169

3 Maintenance


Continued

Cleaning methods

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

i

Protection type

Standard

Foundry Plus

Cleaning method

Vacuum cleaner

Yes

Wipe with cloth Rinse with water

Yes

Yes. With light cleaning detergent.

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

Yes. With light cleaning detergent or spirit.

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

High pressure water or steam

No

Yes i

.

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

Perform according to section

Cleaning with water and steam on page 170 .

Cleaning with water and steam

Instructions for rinsing with water

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

1

I

The following list defines the prerequisites:

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

2

(7 bar)

I

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

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum flow: 20 liters/min

I

Typical tap water pressure and flow

Instructions for steam or high pressure water cleaning

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

2

The following list defines the prerequisites:

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

2

(25 bar)

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

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum water temperature: 80° C

Cables

Movable cables need to be able to move freely:

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

1

2

See

Cleaning methods on page 170

for exceptions.

See

Cleaning methods on page 170

for exceptions.





Cooling fans

3 Maintenance


Continued

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

Inspect the air supply inlet of the the motor cooling fans. Clean to remove any contamination that could hinder the air supply.




171


4 Repair

4.1 Introduction

4 Repair


Structure of this chapter

This chapter describes all repair activities recommended for the IRB 6660 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 373

.


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

Safety on page 19

before commencing any service work.

Note

If the IRB 6660 is connected to power, always make sure that the IRB 6660 is connected to earth before starting any repair work.






173

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.

174




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.





175

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.

176




4 Repair

4.2.3 Mounting instructions for seals

4.2.3 Mounting instructions for seals

General

This section describes how to mount different types of seals.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below describes how to fit rotating seals.

CAUTION

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

• Keep the seal in its original wrappings or protect it well before actual mounting.

• The fitting of seals and gears must be carried out on clean workbenches.

• Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.

1

2

3

4

Action

Check the seal to ensure that:

• The seal is of the correct type (provided with cutting edge).

• There is no damage to the sealing edge (feel with a fingernail).

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

Note

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

Fill 2/3 of the space between the dust tongue and sealing lip with grease. The rubber coated external diameter must also be greased, unless otherwise specified.


Equipment on page 177 .

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.





177

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.

178




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




179

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.

180




4 Repair

4.3.1 Replacement of cable harness, lower end (axes 1-3)

4.3 Complete robot

4.3.1 Replacement of cable harness, lower end (axes 1-3)

Overview

The cable harness 1-6 is undivided.

Replacement of the cable harness is detailed in two steps - lower end (axes 1-3) and upper end (axes 4-6). The procedure below details replacement of lower end of the cable harness. The procedure for replacing the upper end is detailed in section


.

Location of cable harness - lower end (axes 1-3)

The cable harness, lower end (axes 1-3) is located throughout the base, frame and lower arm as shown in the figure below.

xx0700000070

E

F

C

D

G

A

B

Cable guide, axis 2

Metal clamp

Connector at base

Cable guide, axis 1

Cable harness, axes 1-6

Cover plate

Rear cover plate





181

4 Repair


Continued

H Attachment point for earth lug

The motors axes 2-3 are located on either side of the robot as shown in the figure below.

xx0600002599

C

D

E

A

B

Motor, axis 2

Motor, axis 3

Motor attachment screws and washers

Cable gland cover (located on the lower side of the motor)

Motor cover


Equipment, etc.

Cable harness axes

1-6

Spare part no.

Gasket

Standard toolkit

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

Circuit diagram

Art.no.



Note

-

3HAC3537-1 Motor axes 1-5



.


3HAC025744-001 See chapter


.


182




4 Repair


Continued

Removal, cable harness - lower end (axes 1-3)

The procedure below details how to remove the cable harness, lower end (axes

1-3).

1

Action

Move the robot to the calibration position.

Note

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

2

DANGER

Turn off all:




3

4

5

6

Remove the rear cover plate on the robot by removing its attachment screws.

Disconnect the earth cable .

Disconnect connectors R1.MP

and R1.SMB

.

Shown in

Location of cable harness lower end (axes 1-3) on page 181

.

Shown in


.

Shown in


.

Remove the cable guide axis 2.

7

8

9 xx0600002698

• A: Cable guide ax 2

Unscrew the screws in the metal clamps holding the cable harness in the frame and lower arm.

Shown in


Remove the motor cover, axis 1, 2, 3 by removing its attachment screws, in order to reach the connectors.

Disconnect all connectors at motor 1, 2 and 3.




183


4 Repair


Continued

10

Action

Open the SMB cover carefully.

The cable (C) between the battery and the SMB unit may stay connected, in order to avoid an update of the revolution counter. Be careful not to let the weight of the cover strain the cable!

In order to remove the cover completely, the connector R1.G must be disconnected! This causes a necessary updating of the revolution counter!

Note

11

12

Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.

Disconnect X8, X9 and X10 from the brake release unit.

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

Perform this removal with care, in order not to damage any of the components inside the SMB recess.

xx0600002700

• A: SMB battery cover

• B: SMB battery pack

• C: Battery cable xx0600002701

• A: Cable gland, SMB

• B: Attachment screws (4 pcs)


184




4 Repair


Continued

13

Action

Gently pull the cable harness out of base through the cable guide, axis 1 and the frame.

Note

14 Continue removal of the cable harness in the upper arm.

xx0700000154


• B: Metal clamp, frame

• C: Cable guide, axis 1

Detailed in

Replacement of cable harness, upper end on page 196 .





185

4 Repair


Continued

Refitting, cable harness - lower end (axes 1-3)

The procedure below details how to refit the cable harness, lower end (axes 1-3).

1

Action Note

Pull the cable and connectors down through the cable guide axis 1 in the center of the frame.

Make sure the cables are not twisted with each other or with eventual customer harness!

2 Pull out the cables and connectors to the SMB unit through the frame and refit the cable gland with its four attachment screws from inside the

SMB recess.

Perform this refitting with care, in order not to damage any of the components inside the SMB recess.

xx0700000154


• B: Metal clamp, frame

• C: Cable guide, axis 1 xx0600002701


• B: Attachment screws, (4 pcs)


186




4 Repair


Continued

6

7

3

4

5

8

9

Action Note

Reconnect connectors R1.MP

and R1.SMB

at the robot base.

Tightening torque for R1.SMB: 10 Nm.

Attachment points are shown in the figure


.

Reconnect the earth cable .

Refit the rear cover plate on the robot with its attachment screws.

Attachment point is shown in the figure

Location of cable harness - lower end (axes 1-3) on page 181

Shown in the figure

Location of cable harness - lower end (axes 1-3) on page 181

Reconnect all connectors at motor 1, 2 and 3.

Refit the motor cover, axis 1, 2, 3.

Make sure the cabling is placed correctly when refitting the cover and does not get jammed.

Reconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 to the SMB unit.

Reconnect X8, X9 and X10 to the brake release unit.

Reconnect R1.G if it has been disconnected.

Secure the SMB cover with its attachment screws.

If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm.

10

WARNING

Before continuing any service work, please observe the safety information in section

The brake release buttons may be jammed after service work on page 180

!





187

4 Repair


Continued

11

Action

Refit the cable guide, axis 2.

Note

12

13

14

15 xx0600002698

• A: Cable guide axis 2

Pull the cable harness through the lower arm.

Refit the metal clamps holding the cable harness in the frame and lower arm with its attachment screws.

Shown in the figure

Location of cable harness - lower end (axes 1-3) on page 181 .

Continue refitting of the cable harness in the upper arm.

Detailed in section

Replacement of cable harness, upper end on page 196 .

Update the revolution counter!

Detailed in section


16

DANGER



188




4 Repair

4.3.2 Replacement of process cable package 1 - 3 MH

4.3.2 Replacement of process cable package 1 - 3 MH

Location of process cable package axes 1 - 3 MH

The process cable package for axes 1 - 3 MH is located throughout the base, frame and lower arm as shown in the figure below.

xx0700000657

H

J

F

G

C

D

A

B

E

Metal clamp (inside lower arm)

Process cable package, cables

Process cable package, hose

Cable guide

Metal clamp

Connectors at base

Customer plate

Rear cover plate

Earth





189

4 Repair


Continued


Equipment Art. no

Process cable package 1 - 3 MH For spare part number, see


.

Standard toolkit -


Circuit diagram -

-

Note




See


Removal

1

2

The procedure below details how to remove the process cable package 1 - 3 MH.

Action


Note

DANGER


3

CAUTION

The cable package is sensitive to mechanical damage. They must be handled with care, especially the connectors, in order to avoid damaging them.

4 Remove the rear cover plate at the back of the robot base in order to reach the connectors at the base.

Shown in the figure

Location of process cable package axes 1 - 3 MH on page 189 .


190




4 Repair


Continued

5

Action

Disconnect the hose from the customer plate.

Note

6 Disconnect the cable connectors from the customer plate.

xx0700000643

Parts:

• A: Customer plate

• B: Hose connector R1.PROC1

xx0700000645

Parts:

• A: Connector R1.CP/CS

• B: Connector R1.SP/R3.FP7





191

4 Repair


Continued

7

Action

Remove the prev. torque nuts securing the metal clamp of the process cable package, to the metal clamp of the robot cable package, at the SMB recess.

Note

8

9

Pull the lower end of the process cable package out through the centrum hole in gearbox axis 1.

Remove the prev. torque nuts securing the process cable package on the inside of the lower arm.

xx0700000646

Parts:

• A: Metal clamp bracket, robot cable package

• B: Metal clamp bracket, process cable package

• C: Position for prev. torque nuts

Order of removal:

1 Hose

2 Cables xx0700000649

Parts:

• A: Position for prev. torque nuts

• B: Process cable package


192




4 Repair


Continued

10

Action

Disconnect all connectors on the attachment plate.

Note

Refitting xx0700000648

Parts:

• A: Attachment plate

• B: Attachment screws M10x16 quality 8.8-A3F (2 pcs)

• C; Strap, velcro

• D: Connectors

11 Pull the process cable package gently out off the lower arm.

Note

Perform this carefully in order not to damage the cable harness of the robot.

The procedure below details how to refit the process cable package 1 - 3 MH.

1

Action

Push the process cable package gently down through the lower arm.

Note

Make sure that the cables are not twisted with each other.

Note

Perform this carefully in order not to damage the cable harness of the robot.





193

4 Repair


Continued

2

Action

Connect all connectors at the attachment plate.

Note

3 Refit the prev. torque nuts securing the process cable package on the inside of the lower arm.

xx0700000648

Parts:

• A: Attachment plate

• B: Attachment screws M10x16 quality 8.8-A3F (2 pcs)

• C: Strap, velcro

• D: Connectors

4 Push the process cable package gently down through the cable guide in the centrum hole in gearbox axis 1.

xx0700000649

Parts:

• A: Position for prev. torque nuts

• B: Process cable package

Order of refitting:

1 Cables

2 Hose


194




4 Repair


Continued

5

Action

Secure the metal clamp of the process cable package, with the prev. torque nuts on the metal clamp of the robot cable package, close to the SMB recess.

Note

6 Connect all connectors at the customer plate.

xx0700000646

Parts:

• A: Metal clamp bracket, robot cable package

• B: Metal clamp bracket, process cable package

• C: Position for prev. torque nuts

7 Refit the rear cover plate.

8

9

Update the revolution counter.

DANGER


First test run may cause injury or damage on page 28

.

xx0700000645

Parts:

• A: Connector R1.CP/CS

• B: Connector R1.SP/R3.FP7

Shown in the figure

Location of process cable package axes 1 - 3 MH on page 189 .




4 Repair

4.3.3 Replacement of cable harness, upper end

4.3.3 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 1-3)

• upper end (axes 4-6)

This procedure details how to replace the upper end.

For description of how to replace the lower end, see

Replacement of cable harness, lower end (axes 1-3) on page 181

.

Location of cable harness

The cable harness for the axes 4 to 6 runs throughout the upper arm and wrist unit as shown in the figure below: xx0700000071

D

E

F

A

B

C

Cable harness, axes 1-6

Cable bracket, upper arm tube

Cable bracket, wrist unit

Cable starps, outdoor

Attachment screws (cable attachment armhouse), M10x16 quality 8.8 (2 pcs)

Attachment screw (cable attachment rear), M6x25 quality 12.9 Gleitmo


Equipment, etc.

Cable harness axes 1-6

Note

See






4 Repair


Continued

Equipment, etc.

Gasket

Note

Motors axes 1-5

See


Gasket

Retrofit set Foundry Plus, wrist

Retrofit set Foundry Plus, upper arm axis 4

Motor axis 6. Recommended to be changed for Foundry Plus.

See


See


See


.

Standard toolkit Content is defined in section


.

Other tools and procedures may be required.

See references to these procedures in the step-by-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 353

.


Pendulum Calibration in Operating manual - Calibration Pendulum .

If the robot is to be calibrated with fine calibration:

Remove all external cable packages

(DressPack) and tools from the robot.

Removal

The procedure below details how to remove the cable harness.

1

Action

Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.

Note




197


4 Repair


Continued

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

Note

Axis 5 must be oriented in the correct position (+90°) to allow the cover of motor axis 6 to open.

3

DANGER

Turn off all:





4

5

Before starting the removal of the axes-4-6 cable harness, first remove the cable harness of axes 1-3.


Replacement of cable harness, lower end (axes 1-3) on page 181

.

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.

xx0700000140

• A : Cover, wrist unit xx1400002580


198




4 Repair


Continued

6

Action

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.

Note xx0600003034

• A : Cable holder

• B : Attachment screws M6x16, 8.8

(2 pcs)

• C : Attachment screw M4x12, 8-

A2F (securing the carrier)

7

8

9

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 .

Disconnect all connectors at motor axis 6

R2.MP6

and R2.FB6

.

10

11

Loosen the cable bracket in the upper arm tube by undoing its two attachment screws on top of the tube.

Disconnect the two connectors (R2.FB5 and

R2.MP5) inside the tube.

Shown in the figure

Location of cable harness on page 196

Shown in the figure


12

13

14 xx0700000072

Parts:

• A: Motor axis 5 with connectors

R4.FB5 and R4.MP5

• B: Connectors R2.FB5 and R2.MP5

• C: Upper arm tube

Remove eventual cable straps from the harness.

Remove the cover motor axis 4 by removing its attachment screws.

Disconnect all connectors at motor axis 4

(R2.MP4, R2.FB4).

Shown in the figure





199


4 Repair


Continued

15

16

Action

Remove the metal clamps , on the armhouse.

Foundry Plus

Remove the Foundry Plus arm house cover.

Note

Refitting

17

18

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

The procedure below details how to refit the cable harness.

1

2

3

Action

Begin by refitting the cable harness lower end (axes 1-3).

Note



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

Arrange the cable harness as shown in the figure


Refit the cable gland securing the cables to the armhouse.

Make sure not to twist the harness.

4 Connect the two connectors inside the upper arm tube, (R2.MP5 and R2.FB5) and secure the cable bracket with its two attachment screws to the tube.

xx0700000041


200




4 Repair


Continued

5

6

7

8

Action Note

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 axis 4

(R2.MP4,R2.FB4) .

Refit cover motor axis 4.

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.

9

10

11

12 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.

Refit the metal clamps , on the armhouse.

Standard

Fit the wrist cover.

xx0700000140

• A : Cover, wrist unit





201

4 Repair


Continued

13

Action

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

14 Foundry Plus

Make sure the washers are fitted in the gasket holes.

xx1400002579

15

16

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 xx1400002581


202




4 Repair


Continued

17

Action

Foundry Plus

Fit the Foundry Plus cover on the adapter ring.

Note xx1400002582

18

19

20

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


Updating revolution counters on page 348

.

Make sure the gasket on the adapter ring is undamaged. Replace if damaged.

Recalibrate the robot.

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 352 .

General calibration information is included in section


.

21

DANGER



.




203

4 Repair

4.3.4 Replacement of cabling, axis 5 motor

4.3.4 Replacement of cabling, axis 5 motor

Location of cabling

The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in the figure below.

IRB 6660 - 100/3.3, IRB 6660 - 130/3.1

IRB 6660 - 205/1.9

xx0700000055

A

B

Motor axis 5 with connectors R4.FB5 and R4.MP5

Connectors R3.FB5 and R3.MP5

xx0700000632

A

B

C

Cable cover

Motor axis 5 with connectors R4.FB5 and R4.MP5

Connectors R3.FB5 and R3.MP5


Equipment

Cable harness axis 5

Spare part no.

See


.

Note





4 Repair


Continued

Equipment

Circuit diagram

Standard toolkit


Spare part no.

3HAC025744-001

Note



.


Removal, cabling axis 5 motor

The procedure below details how to remove the cabling from the axis 5 motor.

Action Note

1

DANGER

Turn off all:





2

3

4

5

6

Remove the complete wrist unit.

Remove the cover of motor, axis 5.

Disconnect all connectors at motor, axis 5.

Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

Remove the cable, axis 5.

Detailed in section:

•

Removal, wrist unit on page 223 .

Refitting, cabling axis 5 motor

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

Action Note

1

DANGER

4

5

2

3

Turn off all:





Reconnect all connectors at motor, axis 5.

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

Refit the cover of motor, axis 5.

Refit the complete wrist unit.

Detailed in section:

•

Refitting, wrist unit on page 225 .




205


4 Repair


Continued

6

Action

Re-calibrate the robot.

7

DANGER



Note

This is done if a new wrist has been fitted.

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



.

206




4 Repair

4.3.5 Replacement of complete arm system

4.3.5 Replacement of complete arm system

Location of arm system

The complete arm system is defined as the complete robot except for the base and axis-1 gearbox. This is shown in the figure below.

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


IRB 6660 - 100/3.3, IRB 6660 - 130/3.1

xx0700000073

F

G

D

E

H

A

B

C

Upper arm

Lower arm

Motor, axis 1

Frame

Base

Gearbox, axis 1

Attachment screws base M12x70, quality 12.9 Gleitmo (24 pcs)

Calibration plate axis 1





207

4 Repair


Continued

IRB 6660 - 205/1.9

xx0700000633

C

D

E

A

B

F

G

H

Upper arm

Lower arm

Frame

Motor, axis 1

Gearbox, axis 1

Attachment screws base M12x70, quality 12.9 Gleitmo (24 pcs)

Base

Calibration plate axis 1


Equipment, etc.

Lifting accessory, robot

Guide pins M12 x 130

Art. no.

3HAC15607-1

3HAC022637-001

Note

Instruction 3HAC15971-2 is enclosed!

Used to guide the complete arm system when lifting it.

Always use the guide pins in pairs!

In order to make the refitting easier, it is recommended to use two guide pins of different lengths. Notice that longer guide pins than 140 mm will not be possible to remove from the frame because lack of space after refitting!





4 Repair


Continued

Equipment, etc.

Roundsling 1,5 m

Isopropanol

Standard toolkit -

-

Art. no.

Note

Lifting capacity 1,000 kg

Used for cleaning mounting surfaces.



.






1

Action




Note







Axis Calibration in


.






Removal, arm system

Use this procedure to lift and remove the complete arm system.

1

Action


Note





209

4 Repair


Continued

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


xx0700000137

42° xx0700000518

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

4

DANGER

Turn off all:





5

6

7

Drain the oil from gearbox axis

1.

Detailed in section

Changing oil, axis-1 gearbox on page 146

.

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






4 Repair


Continued

8

9

Action

Remove the motor, axis 1.

Note

Detailed in section

Replacing motor, axis 1 on page 274 .

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



Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting accessory!

Follow the instructions before lifting!

IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

xx0700000004

IRB 6660 - 205/1.9


3HAC028197-001 Revision: S xx0700000427

A: Load hook

B: Swiveling lifting eyes (4 pcs)

C: Shortening hook

D: Chain

E: Lifting eye M12

F: Eye of lifting accessory

I: Lifting slings (4 pcs)

L: Hook


211


4 Repair


Continued

Action

10 Remove the block for calibration and calibration plate axis 1 from the bottom of the frame.

Note

11 Unfasten the arm system from the base by unscrewing its 24 attachment screws.

xx0600002734

• A: Block for calibration

• B: Calibration plate axis 1

Shown in the figure

Location of arm system on page 207

.

xx0600003070

Parts:

• A: Serrated lock washer

• B: Gearbox axis 1

• C: Attachment screws M12x80

12 Fit two guide pins in two opposite screw holes.

Art. no. is specified in section


.

13

CAUTION

The complete arm system weighs 1330 - 1520 kg! All lifting equipment used must be sized accordingly!


212




4 Repair


Continued

Action Note

14 Lift the arm system carefully and secure it in a safe area.

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

Continue lifting even if the arm system turns out to be unbalanced despite earlier adjustments! The risk of damaging the interfaces is bigger if the load is lowered unbalanced!

Make sure all hooks and attachments stay in the correct position while lifting the arm system and that the lifting accessory does not wear against sharp edges.

Refitting, arm system

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

Action Note

1

DANGER

Turn off all:









213

4 Repair


Continued

2

Action

Fit the lifting accessory as detailed in enclosed instruction.

Note



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!

IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

xx0700000004

IRB 6660 - 205/3.1


214 xx0700000427

• A: Load hook

• B: Swiveling lifting eyes (4 pcs)

• C: Shortening hook

• D: Chain

• E: Lifting eye M12

• F: Eye of lifting accessory

• I: Lifting slings

• L: Hook




4 Repair


Continued

Action Note

3

4

5

6

CAUTION

The complete arm system weighs 1330 -

1520 kg! All lifting equipment used must be sized accordingly!

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 .

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

Clean the mounting surfaces with isopropanol.

Fit the two guide pins to the frame attachment holes, as shown in the figure to the right.

7

8 xx0600002632

The figure above shows the frame, view from below.

• A: Attachment holes for the guide pins, M12

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

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

Lower the arm system with guidance from the guide pins previously fitted to the frame.

This is a complex task to be performed with utmost care in order to avoid injury or damage!

Note

The refitting must be made completely level!

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

9 Refit 22 of the 24 attachment screws before the arm system is completely lowered.




215


4 Repair


Continued

Action Note

10 Remove the guide pins and secure the arm system to the base with its 24 attachment screws and washers.

Shown in the figure

Location of arm system on page 207 .

M12 x 70, tightening torque: 115 Nm.

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


before fitting.

11 Refit the block for calibration at the bottom of the frame.

Also refit the axis 1 calibration plate .

216

12

13

14

15

16

Refit the axis-1 motor

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

Refit the cabling in the base.


.

Refill the gearbox with lubricating oil.

17

DANGER



xx0600002734

• A: Block for calibration

• B: Calibration plate axis 1

Detailed in section

Replacing motor, axis

1 on page 274

.

Detailed in section

Performing a leakdown test on page 174

.

Detailed in section


Detailed in section


.





Calibration on page 341 .




4 Repair

4.4.1 Replacing the turning disk

4.4 Upper and lower arms

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 axis-6 gearbox for robot variant IRB 6660 - 100/3.3 and IRB

6660 - 130/3.1, and includes cooling elements on motor. There are no cooling elements on the axis-6 motor on robot variant IRB 6660 - 250/1.9.

xx0700000163

A

B

C

D

E

F

Wrist unit

Turning disk

Attachment screws, turning disk (12 pcs)

Oil plug, draining

Oil plug, filling

Cooling elements (IRB 6660 - 100/3.3, IRB 6660 - 130/3.1)


Equipment, etc.

Turning disk

Art. no.

For spare part no.

see:


Note

O-ring

Wrist, type 2

Grease

Flange sealant

Standard toolkit


-

3HAB3772-64 (1 pc)

3HAB3772-61 (12 pcs)

3HAB3537-1

3HAC034903-001

Must be replaced when replacing the turning disk!

Used to lubricate the o-rings.

Loctite 574



.





217


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 217

.

2

DANGER

Turn off all:




3

4

Remove any equipment fitted to the turning disk.

Drain the axis 6 gearbox.

See section

•


5 Remove the attachment screws that secure the turning disk.

6

7

Remove the turning disk .

Foundry Plus:

Remove old flange sealant residues and other contamination from the contact surfaces.

xx1400000994

Shown in the figure

Location of turning disk on page 217

.


218




4 Repair


Continued

Refitting, turning disk

Use this procedure to refit the turning disk.

1

Action Note

Lubricate the o-ring of the turning disk with grease and fit it to the turning disk.

Also fit the 12 o-rings, when refitting the attachment screws.



.

2 Foundry Plus:

Apply Loctite 574 flange sealant on the contact surface.

xx0200000218

• A: Sealing surface, o-ring xx1400000995





219

4 Repair


Continued

3

Action

Secure the turning disk with its attachment screws .

Note

12 pcs, M12 x 30, 12.9 quality Gleitmo.

Tightening torque: 100 Nm.

4

5

Perform a leak-down test of the gearbox axis

6.

Refill the axis 6 gearbox with oil.

xx1400000994



before fitting.


Performing a leak-down test on page 174

.

See section

•


6 Refit any equipment removed during disassembly to the turning disk.

7

DANGER



220




4 Repair

4.4.2 Replacement of complete wrist unit

4.4.2 Replacement of complete wrist unit

Location of wrist unit

The wrist unit is located on the upper arm as shown in the figure below.



IRB 6660 - 100/3.3, IRB 6660 - 130/3.1

xx0700000069

E

F

G

I

H

A

B

C

D

Wrist unit

Turning disk

Cover, wrist unit

Cover, upper arm tube

Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)

Cable bracket

Attachment point for lifting tool, wrist unit

Attachment screws and washers, wrist unit

Upper arm tube





221

4 Repair


Continued

IRB 6660 - 205/1.9

xx0700000635

E

F

C

D

A

B

Wrist unit

Turning disk

Cover, wrist unit

Cover, upper arm tube

Upper arm tube

Attachment screws and washers, wrist unit


Equipment etc.

Wrist unit

Cover for wrist unit


Lifting accessory, wrist unit

Standard toolkit


Circuit diagram

Art. no.



.

Note



.

3HAC13056-3

-

3HAC13605-1

Always use guide pins in pairs!




See chapter

page 389 .

Circuit diagram on


222




4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, wrist unit

2

3

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

1

Action


Note

Remove all equipment fitted to the turning disk.

Turn axis 4 to a position where the cover, upper arm tube and wrist unit, faces upwards. Turn axis 5 to +90°.

xx0200000185





223

4 Repair


Continued

Action Note

4

DANGER

Turn off all:





5

6

7

8

Remove the

Remove the cover, wrist unit .

cover, upper arm tube.

Shown in the figure

Location of wrist unit on page 221 .

Shown in the figure


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

Loosen the cable bracket, wrist unit on top of the wrist by undoing the three attachment screws.

Two of the attachment screws are visibly located at the rear of the bracket and the third located at the bottom of the cable bracket, in the center.

Shown in the figure


xx0200000254

• B: Attachment screws, rear of cable bracket (2 pcs)

• C: Attachment screw, bottom of cable bracket

9

10

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

Fit the lifting accessory to the wrist unit.

11

CAUTION

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



.

12

13

14

15

Slightly raise the wrist unit to unload the screw joint, facilitating removing the attachment screws.

Remove the wrist unit attachment screws and washers .

Shown in the figure


Pull the wrist unit out, lift it away and place it on a secure surface.

Disconnect the motor axis 5 by disconnecting the two connectors in the upper arm tube

(R3.FB5, R3.MP5).

Shown in the figure



224




4 Repair


Continued

Refitting, wrist unit

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

Action Note

1

DANGER

Turn off all:





2

3

Fit two guide pins, M12 in the upper arm tube, in two of the holes for the wrist unit attachment screws.



.

Shown in the figure

Location of wrist unit on page 221

.

Fit the lifting tool to the wrist unit.

Art. no. is specified


.

4

CAUTION

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

5

6

7

8

9

10

Lift the wrist unit and guide it to the upper arm tube with help of the guide pins.

Make sure the cabling from motor, axis 5 is safely run into the arm tube and does not get jammed.

Reconnect the motor axis 5 by connecting the two connectors inside the upper arm tube

(R3.FB5, R3.MP5) and secure the cable bracket with the two attachment screws to the tube.

Shown in the figure


.

Secure the wrist unit with 10 of the 12 attachment screws and washers .

Shown in the figure


.

12 pcs: M12 x 50, 12.9 quality Gleitmo.




before fitting.

Remove the guide pins and secure the two remaining attachment screws as detailed above.

Remove the lifting tool from the wrist unit.

Note

Axis 5 must be oriented in the correct position

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




225


4 Repair


Continued

11

12

Action Note

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

In case of excess of cable length:

• put the excess cable in a loop in the area shown in the figure and secure with with cable straps . Cables are longer in order to fit different upper arm lengths.

xx0200000185

Parts:

• A: Cable straps

Fasten the cable bracket at top of the wrist unit with three attachment screws . Two of them are visible at the rear attachment point and the third is located on the bottom of the cable bracket, in the center.

Shown in the figure


.

226

13

14

15

16

17 xx0200000254

• B: Attachment screws, rear attachment point of cable bracket

(2 pcs)

• C: Attachment screw, bottom of cable bracket

Reconnect the connectors to the axis-6 motor and refit the motor cover.

Refit the cover, upper arm tube.

Shown in the figure


.

Refit the cover, wrist unit.

Re-calibrate the robot!

Shown in the figure


.

Tightening torque: 14 Nm±10%. Screw

3HAB3409-25 (with Loctite), Washer

3HAC062379-001.

Pendulum Calibration is described in

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





Refit any equipment previously removed from the turning disk.

18

DANGER



.




4.4.3 Replacement of upper arm

Location of upper arm

The upper arm is located as shown below.

IRB 6660 - 100/3.3, IRB 6660 - 130/3.1

4 Repair

4.4.3 Replacement of upper arm xx0700000059

C

D

A

B

E

Upper arm

Motor, axis 4

Balancing device

Lower arm

Parallel rod





227

4 Repair

4.4.3 Replacement of upper arm

Continued

IRB 6660 - 205/1.9

xx0700000636

A

B

C

D

Upper arm

Upper arm

Lower arm

Parallel rod


228




4 Repair


Continued

View of the assembly of the upper arm components

Shown below is a cut away view of how the upper arm is fitted to the lower arm

(seen from above). The letters are being referred to in the following step by step procedures.

IRB 6660 - 100/3.3, IRB 6660 - 130/3.1

xx0700000058

I

G

H

E

F

A

B

C

D

J

K

L

Shaft, axis 2

Shaft, axis 3

Set screw, cup point M10 x 20 quality 45H-A3F

Lubricant paste (Molycote 1000)

Sealing ring (V-ring)

Sealing ring

Taper roller bearing

O-ring

Sealing ring

Sealing assembly

Lock nut (KM12)

O-ring (Di = 54.2 mm, t = 5.7 mm)





229

4 Repair


Continued

IRB 6660 - 205/1.9

xx0700000637

F

G

D

E

H

A

B

C

K

L

I

J

Shaft, axis 2

Shaft, axis 3

Set screw, cup point M10x20 quality 45H-A3F

Surfaces where to apply lubricant paste (Molycote 1000)

Sealing ring (V-ring)

Sealing ring

Taper roller bearing

O-ring

Sealing ring

Sealing assembly (including support ring)

Lock nut (KM12)

O-ring (Di = 54.2 mm, t = 5.7 mm)





4 Repair


Continued


Equipment, etc.

Upper arm, axis 4

Grease filling tool

Rust preventive

KM12 socket

Standard toolkit


Circuit diagram -

Art.no.

For spare part part number, see


Note

-

-

3HAC034903-001

3HAC5347-1

Mercasol 3110 Waxcoat



.


See chapter

page 389

.

Circuit diagram on




1

Action Note










Axis Calibration in


.










231

4 Repair


Continued

Removal, upper arm

The procedure below details how to remove the upper arm.

1

2

3

Action


Note

Remove all equipment fitted to the turning disk.

Move the upper arm to a horizontal position.

IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

Rotate axis 4 so that the attachment hole for lifting eye is facing upwards.

xx0700000137

IRB 6660 - 205/1.9

42°

4

DANGER

Turn off all:




5 Secure the upper arm with lifting slings in an overhead crane.

xx0700000518


232




4 Repair


Continued

6

7

Action

Drain the oil from axis 4.

Note

Detailed in section


.

Remove the cable harness in the upper arm.

Detailed in section


8

CAUTION

The complete upper arm weighs 380 kg without any additional equipment fitted!

Use a suitable lifting accessory to avoid injury to personnel!

9

10

11

Raise the lifting equipment to take the weight of the upper arm.

(Not applicable to robot variant IRB 6660

- 205/1.9! )

Remove the balancing device .

Detailed in section


Remove the parallel rod.

Detailed in section

Replacing the parallel rod on page 238

12 Remove the lock nut (K) on the shaft, axis

3 (B).

Shown in the figure

View of the assembly of the upper arm components on page 229 .

13

14

15

16

17

Remove the set screw (C) holding the shaft .

Shown in the figure


Remove the shaft axis 3 (B).

Shown in the figure


Perform the removal with care. Threads can otherwise be damaged!

Shown in the figure


Then remove the shaft, axis 2 (A) in the same order:

1 Remove the lock nut (K)

2 Remove the set screw (C) holding the shaft

3 Remove the shaft axis 2 .

Put the shafts in a clean and safe place.

Remove the upper arm .

Preparations before refitting, upper arm

The procedure below details the preparations which must be done before refitting the upper arm.

1

2

Action Note

Put the shafts (A & B) on a workbench and fit the sealing rings (E).

Shown in the figure


Apply some grease on the shafts and sealing rings .

Note

Don´t apply grease on the threads and cones of the shafts!




233


4 Repair


Continued

3

4

5

Action

Fill the bearings (G) with bearing grease.

Use grease filling tool.

Note

Art. no. is specified


Shown in the figure


Apply lubricant paste (D) on the threads and cones of the shafts .

Molycote 1000.

Shown in the figure

View of the assembly of the upper arm components on page 229

Foundry Plus:

Apply rust preventive on the surfaces on the shaft, according to illustration.

Note

Apply rust preventive to the shafts on both sides of the robot.

xx1400001124

Refitting, upper arm

The procedure below details how to refit the upper arm.

1

Action

Secure the upper arm with lifting slings in an overhead crane.

Note

2

CAUTION

The complete upper arm weighs 380 kg without any additional equipment fitted!

Use a suitable lifting accessory to avoid injury to personnel!


234




4 Repair


Continued

3

Action

Lift the upper arm with an overhead crane and move it to its mounting position.

Make sure that the upper arm is placed in a horizontal position.

Note

IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

xx0700000137

IRB 6660 - 205/1.9

42° xx0700000518

4

Note

Refit the axis 3 side first!

5

6

7

8

9

Carefully refit the shaft, axis 3 (B) by hand only.

Do not use force since the threads can be damaged if fitting is not done in the correct way.

Shown in the figure


Secure the shaft.


Refit the sealing ring (F) on the shaft .



Refit the bearing (G) on the pressing tool, upper arm.

shaft with the

Shown in the figure


Shown in the figure


Fit an o-ring (H) on the sealing ring (I) and fit it on the shaft .

Shown in the figure


Note

The o-ring shall be faced against the bearing .




235


4 Repair


Continued

10

11

12

13

Action Note

Fit the o-ring (L) on the sealing assembly

(J) and refit the sealing assembly on the shaft .

The refit the axis 2 side in the same order with the exception of the lock nut (K).

Shown in the figure


Apply locking liquid on the lock nut (K) and refit it.

Shown in the figure


Loctite 243.

Tightening torque 90 Nm.

Follow the steps for refitting shaft axis 3 above.

Shown in the figure


.

Apply locking liquid on the lock nut (K) and refit it.

Note

The order of the tightening torques is very important!

Shown in the figure


Loctite 243.

Tightening torque the first time: 300 Nm

Tightening torque the second time: 90

Nm

Note

The fitting of the lock nut on axis 2 is performed in three steps:

1 Fit the lock nut with a tightening torque of 300 Nm.

2 Unscrew the lock nut .

3 Fit the lock nut once again. This time with a tightening torque of 90 Nm.

14

15

16

17

18

19

Apply locking liquid in the holes for the set screws (C) and fit the screws.

Shown in the figure


Loctite 243.


Wipe residual grease from the shafts .

Refit the parallel rod .

Detailed in section


Refit the cable harness, upper end .

(Not applicable to the robot variant IRB

6660 - 205/1.9! )

Refit the balancing device .


Detailed in section


Detailed in section








236




Action

20

DANGER



.

Note

4 Repair


Continued




237

4 Repair

4.4.4 Replacing the parallel rod

4.4.4 Replacing the parallel rod

Location of parallel rod

The parallel rod is located as shown in the figure.

xx0700000064

A

B

C

Robot variant IRB 6660 - 205/1.9

Robot variant IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

Parallel rod


Equipment, etc.

Parallel rod

Art.no.

For spare part no. see:

•


.

Note

Mounting/Demounting tool 3HAC5021-1

Locking liquid

Rust preventive

3HAB7116-1

3HAC034903-001

Protection plug

Standard toolkit -

3HAC4836-2

Loctite 243


F21 28x22, 4x12x9



.





4 Repair


Continued

Equipment, etc.


Art.no.

Note


Removing, parallel rod

Use this procedure to remove the parallel rod. The procedure is the same in both ends of the parallel rod.

Action Note

1

DANGER

Turn off all:




2

CAUTION

Secure the upper arm with a roundsling in an overhead crane or similar, in order to avoid accidents.

3 Foundry Plus:

Remove the protection plugs





239

4 Repair


Continued

4

Action

Remove the upper lock screw and washer , that secure the parallel rod in position.

Note

5 xx0700000066

Parts:

• A: Lock screw M6x16, (upper)

• B: Lock screw M6x16, (lower)

Remove the upper shaft (A) and cover washer (B), using the fitting/removing tool .



6 Remove the thrust washer (F).


240


xx0700000065

Parts:

A Shaft

B Cover washer

C Parallel rod

D Sealed spherical bearing

E Bearing grease

F Thrust washer

See figure above!



4 Repair


Continued

Action Note

7

CAUTION

The parallel rod weighs 45 kg.


8

9

10

11

12

Move the parallel rod backwards from its upper connection point and let it rest against the frame and base.

Remove the parallel rod from the robot.

Replace the bearings (D), if necessary.

See figure above and

rod on page 238

!

Secure the parallel rod with a roundsling in an overhead crane or similar.

Remove the lower end of the parallel rod in the same way as the upper end:

1 Remove the lower lock screw and washer.

2 Remove the lower shaft (A )and cover washer (B).

3 Remove the thrust washer (F).

See figure above!

See figure above!

Location of parallel

Refitting, parallel rod

Use this procedure to refit the parallel rod. The procedure is the same in both ends of the parallel rod.

1

2

Action

Start by refitting the lower end.

Verify that the bearings are in correct position in the parallel rod.

Note

3

CAUTION

The parallel rod weighs 45 kg.


4

5

Lift the parallel rod to the mounting position of the lower end, and let it rest on the the frame and base.

Foundry Plus:

Apply rust preventive on the highlighted areas.

Note

Rust preventive should be applied in both ends of the parallel rod.

xx1400001126





241

4 Repair


Continued

6

Action

Put the thrust washer (F) on the axis 2 side of the parallel rod (C).

Note

7

8

9

10 xx0700000065

Parts:

A Shaft

B Cover washer

C Parallel rod

D Sealed spherical bearing

E Bearing grease

F Thrust washer

Put the cover washer (B) on the axis 3 side of the parallel rod.

See figure above!

Refit the shaft (A) by pressing it through the parallel bar with the fitting/removing tool .



.

See figure above!

Loctite 243 Apply locking liquid in the hole of the lock screw.

Refit the lock screw and plain washer.


242 xx0700000066

Parts:

• A: Lock screw M6x16, (upper)

• B: Lock screw M6x16 (lower)




11

12

13

Action

Lift the parallel rod up into position for fitting the upper end.

Refit the upper end of the parallel rod in the same way as the lower end.

Foundry Plus:

Refit the protection plugs.

Note

14

DANGER



.

4 Repair


Continued




243

4 Repair

4.4.5 Replacing the complete lower arm

4.4.5 Replacing the complete lower arm

Location of lower arm

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

xx0700000067

A

B

Lower arm

Parallel arm


Equipment, etc.

Lower arm

Sealing, axes 2/3

Guide sleeves

Crank

Lock screw

Lifting tool, lower arm complete

Art.no.


•


Note

3HAC14446-1

Always change the sealing.

Used to keep the axes 2/3 sealing in place during refitting of lower arm.

-

3HAC023132-001

3HAC8446-1

M16x90





4 Repair


Continued

Equipment, etc.

Standard toolkit


Circuit diagram

-

Art.no.

Note



.


See chapter


.




1

Action Note










Axis Calibration in


.






Removal, lower arm

The procedure below details how to remove the lower arm.

1

Action


Note





245

4 Repair


Continued

Action

2

DANGER

Turn off all:




3 Secure the lower arm with a lock screw in the hole as shown in the figure to the right.

Note

CAUTION

Tighten by hand!

xx1000001101

4

5

6

7

8

9

(Not applicable to robot variant IRB 6660 -

205/1.9 ! )

Remove the balancing device.

Remove the parallel rod.

See


Remove the cable harness in the upper and lower arm.

Secure the cable harness in a way that it is protected from oil spill and damage.

See .

Remove the complete upper arm.

See

Replacement of upper arm on page 227 .

Remove the axes 2 and 3 motors.

See

Replacing the parallel rod on page 238 .

Remove the axes 2 and 3 gearboxes.

See


.

See

Replacing the gearbox, axes 2-

3 on page 324

.

10

CAUTION

The robot lower arm weighs 160 kg (IRB 6660 -

100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660

- 205/1.9).


11 Secure the complete lower arm system (including the parallel arm) with a lifting tool, lower arm complete in an overhead crane or similar.

Specified in






4 Repair


Continued

12

Action

Remove the lock screw that secures the lower arm system.

Note

13 Remove all M12 and M16 screws that hold the lower arm, on both sides.

Note

The axis 3 side has no M16 screws!

14

DANGER

Secure the parallel arm to the lower arm before lifting the lower arm system. If not secured, the parallel arm can fall down and cause a serious accident!

xx1000001101

15

CAUTION

The parallel arm system weighs 92 kg.


xx1000001359





247

4 Repair


Continued

16

Action

Move the parallel arm and secure it to the lower arm as shown in the figure, to prevent it from falling down.

Note xx1000001357

17 The space between the gearboxes is cramp.

Push therefor the lower and parallel arm together with help of an iron bar or similar before removing them.

Note

If the parts are not pushed together, it will be difficult to remove the complete lower arm.

18

CAUTION


100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660

- 205/1.9).


19 Remove the complete lower arm (including the parallel arm).


248


xx1000001358



4 Repair


Continued

20

Action

How to replace the parallel arm is detailed in section

Replacement of parallel arm on page 252

.

Note

Refitting, lower arm

Use this procedure to refit the lower arm system.

1

Action

Fit the parallel arm to the lower arm.

Note

See

Replacement of parallel arm on page 252 .

2

CAUTION


100/3.3, IRB 6660 - 130/3.1) / 110 kg (IRB 6660

- 205/1.9).


3 Fit a lifting tool, lower arm complete , to the lower arm system and lift it up.

Specified in


DANGER

Secure the parallel arm to the lower arm before lifting the lower arm system. If not secured, the parallel arm can fall down and cause a serious accident!

4 Fit two guide sleeves for the axes 2/3 sealings to the lower arm and put the sealings on them.

See figure.



xx1000001368





249

4 Repair


Continued

5

Action Note

Put the lower arm in its mounting position.

If the hole pattern needs to be adjusted, use a crank to move the gears in order to find the correct hole pattern.



xx1000001370

6

Note

Refit the axis 2 side first!

7

8

9

10

Verify that the sealings are still in place.

Refit all screws (both M12 and M16) and washers, that are possible to fit at this stage, on the axis 2 side.

Tightening torque M16: 300 Nm


Push the parallel arm against the axis 3 side with the help of an iron bar or similar.

Refit all screws and washers, that are possible to fit, on the axis 3 side.


Note

The axis 3 side has no M16 screws!

11

12

Remove the guide sleeves and secure two screws more.

Change the position of the lower arm in order to reach the remaining attachment holes, and fit the remaining screws.


250




4 Repair


Continued

13

Action

Secure the lower arm by fitting a lock screw .

CAUTION

Tighten by hand!

Note

Dimension is specified in


xx1000001101

14

15

16

17

18

Refit the axes 2 and 3 gearboxes.

Refit the axes 2 and 3 motors.

Refit the complete upper arm.

Refit the cable harness.

Refit the parallel rod.

See

Replacing the gearbox, axes 2-

3 on page 324

.

See


.

See

Replacement of upper arm on page 227 .

See .

See


See


.

19

20

21

( Not applicable to robot variant IRB 6660 -

205/1.9 ! )

Refit the balancing device.

Remove the lock screw.


22

DANGER






Calibrating with Axis Calibration method on page 352

.






4 Repair

4.4.6 Replacement of parallel arm

4.4.6 Replacement of parallel arm

Location of parallel arm

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

xx0700000067

C

D

A

B



Parallel arm

Lower arm


Equipment, etc.

Parallel arm

VK cover

VK cover

Bearing grease

Rust preventive

Pressing tool, lower arm


252

Art.no.


•


3HAA2166-23

3HAA2166-18

3HAB3537-1

3HAC034903-001

3HAC023092-001

Note

D=120 mm, T=12 mm

D=35 mm, T=8 mm





4 Repair


Continued

Equipment, etc.

Art.no.

Lifting accessory, parallel arm

3HAC023098-001

Lifting accessory, lower arm complete

3HAC8446-1

Level

Standard toolkit -

-


Note







1

Action




Note







Axis Calibration in


.






Removal, parallel arm

Use this procedure to remove the parallel arm.

1

Action


Note




253


4 Repair


Continued

Action Note

2

DANGER

Turn off all:




3 Remove the complete lower arm.

See


.

4 Put the complete lower arm on a workbench as shown in the figure.

Tip

Removal of the parallel arm is best performed on a workbench.

5 Remove the two VK covers.

xx1000001024 xx1000001371


254




4 Repair


Continued

6

Action Note

Fit the lifting accessory, parallel arm on the parallel arm. Lift the parallel arm to the position shown in the figure.



.

xx1000001375

7 Disassemble the parallel arm from the lower arm by using the pressing tool, lower arm .



.

8

CAUTION



9 Remove the parallel arm.

xx1000001018

10 If needed, change the bearings.





255

4 Repair


Continued

Refitting, parallel arm

Use this procedure to refit the parallel arm.

1

2

3

Action

Refitting of the parallel arm is best performed on a workbench.

Note

Apply some arm.

grease on the shafts on the parallel

Refit a spacing sleeve on each shaft.

Specified in


xx1000001376

4 Refit a bearing on each shaft with pressing tool, lower arm .



xx1000001377


256




4 Repair


Continued

5

Action

Foundry Plus:

Apply rust preventive on the highlighted areas.

Note xx1400001127

6

7

8

Refit the protection washer on the inner shaft.

Refit the lock ring on the inner shaft.

CAUTION



9

10

Fit the lifting accessory, parallel arm .



.

Lift the parallel arm onto the workbench where the lower arm is placed.



11

12

Adjust the lower arm in a way that both holes are parallel.

Use a level .

Apply some grease in the holes in the lower arm

(thick blue arrows).

Note

Do not put grease on the surfaces for the VK covers

(thin red arrow)!

xx1000001380





257

4 Repair


Continued

13

Action

Lift the parallel arm, lower it and put it in mounting position with the lower arm.

Note xx1000001379

14 Carefully press the parallel arm onto the lower arm using the pressing tool, lower arm .



.

15

16

Fit the big and small VK cover.

Refit the complete lower arm.

17 Recalibrate the robot.

Detailed in section

Replacing the complete lower arm on page 244 .

Pendulum Calibration is described in Operating manual - Calibration

Pendulum , enclosed with the calibration tools.



.



.

18

DANGER



258




4 Repair

4.5.1 Replacing the SMB unit

4.5 Frame and base

4.5.1 Replacing the SMB unit

Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure.

Required equipment xx0600002621

A

B

C

D

E

SMB cover

SMB unit

Battery cable

SMB battery

SMB battery, cover

Note

There are different variants of SMB units and batteries. The variant with the

3-pole battery contact has longer lifetime for the battery.

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

Equipment, etc.

SMB unit

Battery pack

Article number

For spare part number, see:


For spare part number, see:


Note




259


4 Repair


Continued

Equipment, etc.

Standard toolkit

Circuit diagram -

-




.

See chapter


Removing, SMB unit

Use this procedure to remove the SMB unit.

1

2

Action


DANGER

Turn off all:




Note

3


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


4 Remove the SMB cover by unscrewing its attachment screws.

Shown in the figure

Location of

SMB unit on page 259 .

CAUTION



5

6

7

8

Use caution and remove the connectors X8, X9 and

X10 from the brake release board, if need of more space.

Remove the nuts and washers from the guide pins that secure the board.

Shown in the figure

Location of

SMB unit on page 259 .

Use caution and disconnect the connectors from the

SMB unit when pulling the board out.

Connectors R1.SMB1-3,

R1.SMB4-6 and R2.SMB

Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards.


260


xx1700000993



4 Repair


Continued

Refitting, SMB unit

Use this procedure to refit the SMB unit.

Action

1

DANGER

Turn off all:




Note

2




3

4

5

6

7

Connect the battery cable to the SMB unit.

Make sure the lock on the battery cable connector R2.G snaps into place during refitting.

Shown in the figure

Location of SMB unit on page 259 .

Connect all connectors to the SMB board:

R1.SMB1-3, R1.SMB4-6 and R2.SMB



.

Shown in the figure


Fit the SMB unit onto the guide pins .

Secure the SMB unit to the pins with the nuts and washers.

If disconnected, reconnect the connectors X8,

X9 and X10 to the brake release board.

Be careful not to damage the sockets or pins.

Make sure the connector and its locking arms are snapped down properly.

X9

X8

X10 xx1700000978

8

9

Secure the SMB cover with its attachment screws.

If cabling is used for 7th axis (option), refit the

7th axis connector to the SMB cover and tighten with 6 Nm.

Shown in the figure


Update the revolution counter!

See


.

10

DANGER





261


4 Repair

4.5.2 Replacing the brake release board

4.5.2 Replacing the brake release board

Location of brake release board

The brake release unit is located together with the SMB unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below.

xx0600002621

C

D

E

A

B

SMB cover

SMB unit

Battery cable

SMB battery

SMB battery, cover


Equipment, etc.

Brake release board

Standard toolkit


-


3HAC065020-

001

DSQC1050



.



262




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

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 262

.

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

Open the SMB cover by unscrewing the attachment screws.

Let the battery stay connected, to avoid the need of synchronization of the robot!

Shown in the figure


.

CAUTION



6

7

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

Remove the complete brake release board

(including brake release board and bracket) from the SMB recess, by removing its two attachment screws.





263

4 Repair


Continued

8

Action

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

Note

X9

X8

X10 xx1700000978

Location of the brake release unit is shown in the figure


.

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

Refitting, brake release board

Use this procedure to refit the brake release board.

Action Note

1




2 Connect the connectors X8, X9 and X10 to the brake release board.

Be careful not to damage the sockets or pins.

Make sure the connector and its locking arms are snapped down properly.

X9

X8

X10 xx1700000978

3

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


.



.

Refit the complete brake release board (including brake release board and bracket) to the

SMB recess with the two 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.





4 Repair


Continued

6

Action

Refit the SMB cover with its attachment screws.

7

WARNING

Before continuing any service work, follow the safety procedure in

The brake release buttons may be jammed after service work on page 180 .

Note

Shown in the figure


.

8

9 Refit the cover, push button guard .

10 Press the push buttons 1 to 6, one at a time, to make sure that the buttons are moving freely and do not stay in a locked position.

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

Detailed in the Calibration chapter section


.

12

Refit the push button guard to the SMB cover.

Shown in the figure


.

DANGER






265

4 Repair

4.5.3 Replacing the balancing device

4.5.3 Replacing the balancing device

Note

This section is only applicable to robot variant IRB 6660 - 100/3.3, IRB 6660 -

130/3.1.

Location, balancing device

The balancing device is located as shown in the figure.

xx0700000019

A

B

C

Balancing device

Piston rod

Guide ring (not visible in this figure)


Equipment, etc.

Balancing device

Auxiliary shaft

Auxiliary shaft, long

Art.no.



.

Note

3HAC5281-1

3HAC5275-1

For fitting the inner rings of the bearings





4 Repair


Continued

Equipment, etc.

Auxiliary shaft, short

Lock screw

Art.no.

-

3HAC5276-1

Note

Screw

M16 x 90

For securing the lower arm.

2 pcs, M12 x 50

For neutralizing the spring force of the balancing cylinder.

Lubrication tool

Lifting accessories

Locking liquid

Standard toolkit -

3HAC5222-2

-

3HAB7116-1 Loctite 243



Ball bearing puller -

Removing, balancing device

Use this procedure to remove the balancing device.

1

2

Action Note

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

The balancing device must be placed in a 90° angle from the floor, in order the be lifted in the most secure way.

See the figure in

Location, balancing device on page 266 .

Lock the lower arm by inserting the lock screw into the hole .

CAUTION

Tighten by hand!

3

DANGER

Turn off all:




xx1000001101




267


4 Repair


Continued

4

5

6

Action

Remove the protection hood in the upper end of the balancing device.

Insert two screws, M12x50 in the holes to neutralize the spring force. Screw in the screws until they have proper contact with the cylinder inside.

The length of the cylinder is now locked and the balancing device is unloaded. It should now be possible to easily rotate the balancing device.

Attach a lifting accessories to the balancing device.

Use the hole in the lifting ear.

Note

7 Remove the upper and lower lock nuts and support washers (2+2 pcs).

Note

Make sure that the shaft between the upper and lower arm does not rotate when unscrewing the lock nuts! The lock nut is locked with Loctite

243.

xx1000001112 xx1000001113

8

9


268

Fit the auxiliary shafts on the upper and lower pivot shaft.

Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft.



Stretch the roundsling .




4 Repair


Continued

10

Action Note

Apply a ball bearing puller behind the lower ear of the balancing device.

The figure show IRB 760, but the principle is the same.

Note

The ball bearing puller must be applied around the spacer ring . See figure!

11

CAUTION

The balancing device weighs 70 kg.


12 With the help of the ball bearing puller carefully remove the balancing device from its upper and lower attachments.

xx1000001115

13

14

Remove the balancing device and put it in a safe place.

Remove the inner rings of the bearings.

xx1000001114





269

4 Repair


Continued

15

Action

Remove upper and lower spacer rings and support washers (2+2 pcs).

Note xx1000001116

16 Remove residual grease.

Refitting, balancing device use this procedure to refit the balancing device.

Note

1

2

Action

Check the bearings. Replace if needed.

Refit the inner sealing rings and support washers in both ends.

xx1000001116

3

4

Refit the inner ring of the bearings on the upper and lower pivot shaft with the auxialiary shaft.

Fit the auxiliary shafts on the upper and lower shafts.

Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft.

Art.no. is specified in section



270




4 Repair


Continued

Action

5

CAUTION

The balancing device weighs 70 kg.


6 Attach lifting accessory to the balancing device and lift it on to the auxiliary shafts.

Note

7 Adjust the length between the upper and lower bearings by means of the M12 screws, used to neutralize the spring force.

This length should preferably be 0.5 mm too short than 0.1 mm too long. If the distance is too long the bearings may be damaged when erecting the balancing device.

xx1000001112 xx1000001111





271

4 Repair


Continued

8

Action

Carefully refit the balancing device on the upper and lower shafts.

Note xx1000001271

9

10

11

12

13

14

Fit the lubricating tool .

The tool should be tightened to the bottom position by hand power only.

Art. no. is specified in section


Fill the bearings with grease through the nipple.

Continue until grease excudes behind the inner sealing.

Remove the lubricating tool and wipe off protruding grease.

Remove the auxiliary shafts.

Apply locking liquid on the threads of the lock nuts.

Specified in section


Refit the lock nuts and support washers.

Tightening torque: 120 Nm

15 Check play (min. 0.1 mm) between support washers and bearing seat at both bearings.


272


xx1000001113



4 Repair


Continued

16

17

Action

Remove the M12x50 screws from the balancing device to restore the springforce.

Remove the lock screw .

Note

18

DANGER



xx1000001101




273

4 Repair

4.6.1 Replacing motor, axis 1

4.6 Motors

4.6.1 Replacing motor, axis 1

Location of motor axis 1

The motor axis 1 is located on the left hand side of the robot as shown in the figure.

xx0600002598

A

B

C

D

Motor axis 1


Cable gland cover (located on the left hand side of the motor)

Motor cover


Equipment, etc

Motor axis 1

O-ring

Grease

Loctite 574, Flange sealant

Art.no.

Note

See spare part number in


.

Includes:

• motor

• pinion

• o-ring (Old o-ring must be replaced when replacing the motor)

21522012-430

3HAB3537-1

12340011-116

Replace if damaged.

Used to lubricate the o-ring

Option Foundry Plus





4 Repair


Continued

Equipment, etc

Power supply

Standard toolkit


Circuit diagram

-

-

Art.no.

Note

24 VDC, max. 1,5 A

For releasing the brakes.




See chapter


.




1

Action Note










Axis Calibration in


.






Removing motor axis 1

Use this procedure to remove the axis-1 motor.

1

Action


Note





275

4 Repair


Continued

Action

2

DANGER


3 Remove the motor cover in order to get access to the connectors on top of the motor.

Note

4 Remove the cable gland cover at the motor cable exit.

Note

Make sure the gasket is undamaged! Replace if damaged.

xx1000001092

Part:

Motor cover

5

6 xx1000001094

Part:

Position of Cable gland cover

Disconnect all connectors beneath the motor cover.

In order to release the brake, connect the 24

VDC power supply.

Connect to connector R2.MP1

• + : pin 2

• -: pin 5


276




7

Action

Remove the attachment screws of the motor.

Note

4 Repair


Continued

8 xx1000001090

Parts:

Motor axis 1

Attachment screw (4 pcs)

Washer (4 pcs)

Pinion

If required, press the motor out of position by fitting two screws in the holes on the motor for pressing out the motor.

Always use removal screws and tools in pairs!

9

CAUTION

The motor weighs 29 kg! All lifting equipment used must be sized accordingly!

10 Remove the motor by carefully lifting it straight up to get the pinion away from gear.

CAUTION

Be careful not to damage the pinion in the process!

11

12

13

Disconnect the brake release voltage.

Check the pinion. If there is any damage, the pinion must be replaced.

Foundry Plus:

Remove old Loctite 574 flange sealant residues and other contamination from the contact surfaces on both motor and gearbox.

xx1000001021





277

4 Repair


Continued

Refitting motor axis 1

This procedure describes how to refit motor axis 1.

1

Action

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease .

Note xx1000001096

Parts:

Circumference of motor

O-ring

Note

The o-ring must be replaced when replacing the motor.

2

3

4

CAUTION



VDC power supply.


• + : pin 2

• -: pin 5

Foundry Plus:


xx1400000986


278




4 Repair


Continued

5

Action

Gently lower the motor into the gear, making sure the pinion is properly mated to the gearbox of axis 1.

Note

Note

Make sure the motor is turned the right way.

See figure.

6

7

8

9

Note

Make sure the motor pinion does not get damaged!

xx1000001090

Parts:

Motor axis 1

Attachment screw (4 pcs)

Washer (4 pcs)

Pinion

Secure the motor with its four attachment screws and plain washers .

M10 x 40

Shown in the figure

Location of motor axis 1 on page 274

.

Tightening torque:

• 50 Nm


Reconnect all connectors beneath the motor cover.

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

Note

Make sure the cover is tightly sealed!

Replace gasket if damaged.

10 Refit the motor cover with its attachment screws.

Note


xx1000001094

Part:

Position of Cable gland cover




xx1000001092

Part:

Motor cover


279

4 Repair


Continued

11

Action


12

DANGER



Note







280




4 Repair

4.6.2 Replacing motors, axes 2 and 3

4.6.2 Replacing motors, axes 2 and 3

Location of motors, axes 2 and 3

The motors axes 2 and 3 are located on either side of the robot as shown in the figure.

The procedure is the same for both motors.

xx0600002599

D

E

F

A

B

C

Motor, axis 2

Motor, axis 3


Cable gland cover (located on the lower side of the motor)

Motor cover

Hole for lock screw


Equipment, etc.

Motor axes 2-3

O-ring, motor

Grease


Guide pins

Art. no.

Note



.

Includes

• motor

• pinion

• o-ring (the o-ring must be replaced when the motor is replaced)

21522012-430

3HAB3537-1

12340011-116

3HAC13120-2

Replace if damaged.

For lubricating the o-ring.

Option Foundry Plus

M10x150

For guiding the motor.

Guide pins are to be used in pairs!

Lifting tool, motor axes 2-3 3HAC14586-1

Lock screw M16x90

For securing the lower arm.




281


4 Repair


Continued

Equipment, etc.

Power supply

Rotation tool

-

Art. no.

Standard toolkit


Circuit diagram 3HAC025744-001

Note

24 VDC, 1.5 A


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




See chapter





1

Action




Note







Axis Calibration in


.






Removing motors axes 2 and 3

Use this procedure to remove motors axes 2 and 3.

1

Action


Note


282




4 Repair


Continued

2

Action

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

Note xx1000001101

3 Lock the lower arm by inserting the lock screw into the hole of the frame.

This is done in order to secure axis 2 from collapsing when gearbox axis 2 is being removed.

See figure above.

4

DANGER


5

6

7

Secure the upper arm with roundslings in an overhead crane.

This is done in order to secure axis 3 from collapsing when gearbox axis 3 is being removed.

Drain the oil from gearbox .

See section

•

Draining, axes 2 and 3 on page 151

Remove the motor cover .

xx1000001102





283

4 Repair


Continued

8

Action

.

Remove the cable gland cover at the cable exit

Note

Note

Make sure the gasket is not damaged! Replace if damaged.

xx1000001103

9

10



VDC power supply.


• + : pin 2

• -: pin 5

11 Unscrew attachment screws and washers of the motor.

xx1000001104


284




4 Repair


Continued

12

Action Note

Fit two guide pins in two of the motors attachment holes.



xx1000001131

13 If required, press the motor out of position by fitting two screws in the remaining attachment holes of the motor, diagonal to each other.

Always use the removal screws and tools in pairs!

xx1000001184

14 Remove the two screws and fit the lifting tool, motor axes 2-3 to the motor.



15

CAUTION






285

4 Repair


Continued

16

Action

Pull out the motor to get the pinion away from the gear.

Make sure the pinion does not get damaged!

Note

17

18

19

20

Remove the motor by gently lifting it straight out and place it on a secure surface.

Disconnect the brake release voltage!

Check the pinion. If there is any damage, the motor pinion must be replaced.

Foundry Plus:


xx1000001105 xx1400000988


286




4 Repair


Continued

Refitting, motor

Use this procedure to refit the motors for axes 2 and 3.

1

Action

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.

Note

2

3

4 xx1000001096


VDC power supply.

Parts:

A Circumference

B O-ring


• + : pin 2

• -: pin 5

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



Foundry Plus:


xx1400000987





287

4 Repair


Continued

5

Action

Fit the two guide pins in the two lower motor attachment holes.

Note



xx1000001131

6

CAUTION


7 Lift the motor and guide it on to the guide pins , as close to the correct position as possible without pushing the motor pinion into the gear.

The figure shows IRB 760 but the principle is the same.

Note

Make sure the motor is turned the right way, that is connections for the cables facing downwards.

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

xx1000001185


288




4 Repair


Continued

9

Action

Use the rotation tool in order to rotate the motor pinion when mating it to the gear (see figure).

Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox axis 2-3 and that it doesn´t get damaged.

Note

Note

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

xx0200000165

Part:

A Rotation tool

10

11

Remove the guide pins.

Secure the motor with its attachment screws and plain washers .

12

13

14 xx1000001104

M10 x 40 (4 pcs)




before fitting.




Connect in accordance with markings on connectors.

Note

Use a new gasket!





289

4 Repair


Continued

15

Action

Refit the motor cover with its attachment screws and washers.

Note

Note


16 Remove the lock screw from the hole for lock screw .

xx1000001102 xx1000001101

17

18

Perform a leak-down test of the axis 2 (or 3) gearbox.

Refill the gearbox with oil.

19 Recalibrate the robot.

Detailed in

Filling, axes 2 and 3 on page 151 .











4 Repair


Continued

Action

20

DANGER



Note




291

4 Repair

4.6.3 Replacement of motor, axis 4

4.6.3 Replacement of motor, axis 4

Location of motor

The motor axis 4 is located on the left-hand side of the upper arm as shown in the figure below.

xx0700000061

A

B

Motor, axis 4

Attachment screws M8X25 quality 8.8 (4 pcs)


Equipment, etc.

Motor including pinion

O-ring

Lifting tool, motor ax 1, 4, 5

Grease


Removal tool. motor M10x

Guide pins M8 x 100

Guide pins M8 x 150

Rotation tool

Power supply

Standard toolkit

-

-

Art. no.

Note



.

Includes:

• motor

• pinion

• o-ring 21522012-430

21522012-430 Must be replaced when reassembling motor!

3HAC14459-1

3HAB3537-1

12340011-116

3HAC14972-1

3HAC15520-1

3HAC15520-2

3HAC17105-1

Used to lubricate the o-ring.

Option Foundry Plus

Always use the removal tools in pairs!



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.

Calibration Pendulum toolkit

Art. no.

3HAC15716-1

Calibration tool box, Axis Calibration

3HAC055412-001

Note

Complete kit that also includes operating manual.

Required if Calibration Pendulum is the valid calibration method for the robot.

Delivered as a set of calibration tools.

Required if Axis Calibration is the valid calibration method for the robot.



Circuit diagram 3HAC025744-001 See chapter


.




1

Action Note










Axis Calibration in


.






Removal, motor axis 4

The procedure below details how to remove the motor, axis 4.

1

Action


Note




293


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 154

.

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

Location of motor on page 292

.

Make sure the gasket is not damaged!

Remove the cover on top of the motor by unscrewing its four attachment screws.


In order to release the brake, connect the

24 VDC power supply.


• +: pin 2

• -: pin 5

Unscrew the motors four attachment screws and plain washers.

Shown in the figure

Location of motor on page 292

.

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.

Make sure the motor pinion is not damaged!

13 Foundry Plus:



294 xx1400000989




4 Repair


Continued

Refitting, motor axis 4

The procedure below details how to refit motor, axis 4.

Action Note

1

DANGER

Turn off all:





2

3

4




.

In order to release the brakes, connect the

24 VDC power supply.

Connect to connector R2.MP4:

• +: pin 2

• -: pin 5

Foundry Plus:


xx1400000990

5

6

Fit the two guide pins in two of the motor attachment holes.

Fit the motor with guidance of the pins, making sure the motor pinion is properly mated to the gear of gearbox 4.



.

Shown in the figure

Location of motor on page 292 .






295

4 Repair


Continued

7

Action Note

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

Fit the motor, making sure the motor pinion is properly mated to the gear, axis 4.



.


Make sure the motor is turned the right direction, that is the cables facing forwards.

296

8

9

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.


Secure the motor with 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 four attachment screws.



Shown in the figure

Location of motor on page 292 .

Perform a leak-down test if the gearbox has been drained.


Performing a leakdown test on page 174

.

15

16

Refill the gearbox with oil if drained.

Recalibrate the robot!






.

17

DANGER



.




4 Repair




The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below.



xx0700000062

A

B

C

D

E



Wrist unit

Motor, axis 5 (Inside upper arm tube)

Upper arm tube


Equipment, etc.

Motor

Set of shim, motor

O-ring

Grease

Mineral oil

Art. no.



.

3HAC7941-28

Note

21522012-430

Loctite 574, Flange sealant 12340011-116

Isopropanol

3HAB3537-1

11771012-208

CS 320

Used to obtain the correct distance between motor flange and outer surface of motor pinion.

Must be replaced when reassembling motor!


Option Foundry Plus

For cleaning motor pinion and motor pinion hole.

For lubrication of pinion shaft and pinion hole.




297


4 Repair


Continued

Equipment, etc.

Art. no.

Removal tool, motor M10x 3HAC14972-1

Measuring tool 6896134-GN

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


.







298




4 Repair


Continued

Removal, motor, axis 5

The procedure below details how to remove motor, axis 5.

1

Action


Note

2

DANGER

Turn off all:





3 Drain the oil from gearbox axis 5.

4 Remove the wrist unit.



.


Removal, wrist unit on page 223

.

xx1400002580

5

6

7

8

9

10

Place the wrist unit safely on a workbench, in a fixture or similar.

Remove the cover on top of the motor by unscrewing its four attachment screws.

Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

Disconnect all connectors beneath the motor cover and remove the cable of the axis-5 motor.

In order to release the brake, connect the 24 VDC power supply.

Connect to either:

- connector R4.MP5 (in the motor):

• + : pin 2

• -: pin 5

- connector R3.MP5 (on the separate cable, if not removed):

• +: pin C

• -: pin D

Remove the motor by unscrewing its four attachment screws and plain washers.




299


4 Repair


Continued

11

12

13

14

15

Action Note

Fit the two guide pins in two of the motor attachment screw holes.



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.

Foundry Plus:


xx1400000991

Refitting, motor, axis 5


Action Note

1

DANGER

Turn off all:





2

3





VDC power supply.

Connect to either:

- connector R4.MP5 (in the motor):

• +: pin 2

• -: pin 5

- connector R3.MP5 (on the separate cable, if not removed):

• +: pin C

• -: pin D


300




4 Repair


Continued

4

Action

Foundry Plus:


Note xx1400000991

8

9

5

6

7

10

11

12

13

14




Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of axis 5.


Secure the motor with four attachment screws and plain washers.

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 cover on top of the motor with its four attachment screws.


Perform a leak-down test.



.

Refit the wrist unit.

Foundry Plus

Make sure that the gasket is undamaged. Also the small gasket fitted in the cover recess.

Replace if damaged.

xx1400002579





301

4 Repair


Continued

15

Action

Foundry Plus

Make sure the washers are fitted in the gasket holes. Refit the cover, wrist unit Foundry Plus.

Note xx1400002580

16

17

Refill the gear with oil.


18

DANGER





.







302




4 Repair




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

B

C

D xx0700000068

A Axis-6 motor. Figure shows a motor with cooling elements. (There are no cooling elements on the motor on variant IRB 6660 - 205/1.9.)

Axis-6 gearbox

Attachment screws and washers gearbox (18 pcs)

Attachment screws, turning disk (12 pcs)


Equipment, etc.

Motor, axis 6

O-ring

Gasket

Gasket, cover

Removal tool, motor

M10x

Guide pins M8 x 100

Spare part no.



.

21522012-430

3HAC048560-001

3HAC033489-001

Art. no.

3HAC14972-1

3HAC15520-1

Note

Includes:

• motor

• pinion

• o-ring

Must be replaced when reassembling motor!

Must be replaced when replacing motor

Must be replaced when opening cover.






303


4 Repair


Continued

Equipment, etc.

Guide pins M8 x 150

Power supply

Spare part no.

Grease


Standard toolkit


Calibration tool box,

Axis Calibration

-

Art. no.

3HAC15520-2

3HAB3537-1

12340011-116

Note


24 VDC, 1.5 A



Option Foundry Plus

-

3HAC15716-1

3HAC055412-

001



.






Other tools and procedures may be required.

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

Circuit diagram 3HAC025744-

001

See chapter





1

Action




Note







Axis Calibration in


.







4 Repair


Continued

Action




Note

Removal, motor

The procedure below details how to remove the motor, axis 6.

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 308 .

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.

In order to release the brake, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5





305

4 Repair


Continued

7

Action

(Not applicable to robot variant IRB 6660 - 205/1.9

!)

If needed, loosen the strap securing the cooling elements in order to reach the attachment screws securing motor axis 6.

Note

8

9 xx0700000164

• A: Strap

• B: Cooling element.

Remove the motor by unscrewing its four attachment screws and plain washers.

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



.


10 Lift the motor carefully to get the pinion away from the gear and disconnect the brake release voltage.


11 Remove the motor by gently lifting it straight out.

Refitting, 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 308 .

1

2

3

4

5

6

Action


Note




VDC power supply.


• +: pin 2

• -: pin 5




Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of gearbox, axis 6.

Make sure the pinion on the motor shaft is not damaged!


Secure the motor with its four attachment screws and plain washers.

4 pcs: M8 x 25, tightening torque: 24

Nm.





4 Repair


Continued

7

Action

(Not applicable to robot variant IRB 6660 -

205/1.9!)

Refit the strap securing the cooling elements.

Note

8

9

10

11 xx0700000164

• A: Strap

• B: Cooling elements



Refit the cover on top of the motor with its five attachment screws.







.



12

DANGER







307

4 Repair


Continued

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 305

.

xx1500002524

• A: Motor unit

• B: Connection box

• C: Attachment screw (5 pcs)

• D: Rear motor cover

• E: Gasket

4

Note

Keep the old rear motor cover with the air nipple.


308




4 Repair


Continued

5

Action


Note

6 Remove the protection strip on the gasket and mount it on the motor .

xx1400000992

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





309

4 Repair


Continued

8

Action


Note

9

10

Apply grease on the o-ring on the motor .

Continue to refit the new motor according to section,

Refitting, motor on page 306

.

xx1400000992

310




4 Repair

4.7.1 Replacing the axis 1 gearbox

4.7 Gearboxes

4.7.1 Replacing the axis 1 gearbox


The axis 1 gearbox is located between the frame and base as shown in the figure.

xx0700000074

A

B

C

D

E

Gearbox, axis 1

Frame

Base

Attachment screws gearbox axis 1, M12x70 quality 12.9 UNBRAKO (24 pcs)

Attachment screws gearbox axis 1, M16x90 quality 12.9 UNBRAKO (18 pcs)


Equipment, etc.

Gearbox

O-ring

O-ring

Sealing ring

Grease

Art. no.

For spare part no.

see:

•


.

Note

Includes:

• gearbox

• all o-rings and sealing rings

3HAB3772-54

3HAB3772-55

3HAC11581-4

3HAB3537-1

Replace if damaged!

Replace if damaged!

Replace if damaged!

For lubricating the o-rings.




311


4 Repair


Continued

Equipment, etc.

Support, base and gear 1

Lifting accessory, base

Lifting accessory

(chain)

Guide pins



Axis Calibration

Standard toolkit

Art. no.

3HAC15535-1

3HAC15560-1

Note

3HAC15556-1

-

3HAC15716-1

3HAC055412-001

2 pcs, M16x150.

Used for guiding the gearbox into place in the base.



Required if Calibration

Pendulum is the valid calibration method for the robot.










1

Action




Note


312




4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, gearbox axis 1

Use this procedure to remove gearbox, axis 1.

1

Action


Note





313

4 Repair


Continued

2

Action

Move the robot to its most stable position, shown in the figure to the right.

Note

IRB 6660 - 130/3.1, IRB 6660 - 100/3.3

xx0700000137

IRB 6660 - 205/1.9

42° xx0700000518

3

4

5

6

DANGER

Turn off all:




Drain the axis 1 gearbox.

Remove the complete arm system.

Unfasten the robot base from the foundation by removing the base attachment screws.

See

Changing oil, axis-1 gearbox on page 146 .

Detailed in section

Removal, arm system on page 209

.





7

Action

Attach the lifting accessory, base and gear

1 and the lifting tool (chain) to the gearbox and base.

Note

4 Repair



Specified in


8

CAUTION

The base and axis 1 gearbox weighs 310 kg + 200 kg.


9

10

Lift the robot base including the axis 1 gearbox to allow the base and gear 1 support be fitted on each sides of the base.



.

Secure the support to the base and to the foundation.

Make sure the base remains in a stable position before performing any work underneath the base!

xx1000000364

A Support base (4 pcs)





315

4 Repair


Continued

11

Action

Remove the bottom plate from underneath the base in order to get access to the attachment screws.

It may be necessary to also remove the rear connector plate.

Note xx1000001385

12 Unscrew the attachment screws and remove the washers.

xx0300000612

A Bottom plate

B Rear connector plate

C Attachment screw

D Groove


316 xx0200000227

A view from below:

• A: Oil drain hose

• B: Attachment screws, gearbox axis 1, 18 pcs

• C: Washers, 3 pcs




13

Action

Remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws.

Note

4 Repair


Continued

14

CAUTION

The gearbox weighs 200 kg.


15

16

Lift the gearbox away with the already mounted lifting tools.

Turn the gearbox, and remove the protection pipe by unscrewing two attachment screws.

Note

Move the protective pipe over to the new gearbox.

xx1000001387 xx1400000786





317

4 Repair


Continued

Refitting, gearbox axis 1

Use this procedure to refit gearbox, axis 1.

1

Action Note

Fit the support, base and gear 1 to the base.

Mounting of the support, base and gear

1 is detailed in section

Removal, gearbox axis 1 on page 313 .

2 xx1000000364

A Support base (4 pcs)

Make sure the two o-rings on the circumference of the gearbox are seated properly in their respective groove. Lubricate them with grease .

Art no. is specified in


xx0200000055

• A: Guide pin

• C: O-ring 3HAB 3772-54

• D: O-ring 3HAB 3772-55

• E: Sealing ring 3HAC 11581-4


318




4 Repair


Continued

3

Action

Make sure the small o-ring around the oil hole is fitted properly!

Note

4 xx1000001392

Attach the lifting accessory, base and gear 1 and the lifting tool (chain) to the gearbox.

Specified in


.

5 xx1000001395

Fit two guide pins in two of the attachment holes in the gearbox, parallel to each other.

Specified in


.

6

CAUTION






319


4 Repair


Continued

7

Action

Lift the gearbox.

Make sure the guide pin in the bottom face of the gearbox is properly aligned with the base.

Note xx1000001389

8 xx1000001391

Lift gearbox axis 1 onto the guide pins and lower it carefully to its mounting position.



320




4 Repair


Continued

9

Action

Secure the gearbox with its attachment screws and washers.

Note

18 pcs, M16 x 90, 12.9 quality UN-

BRAKO.




before fitting.

10 Refit the cable guide in the center of gearbox

1 with its attachment screws.

xx0200000227

A view from below:

• A: Oil drain hose

• B: Attachment screws, gearbox axis 1, 18 pcs

• C: Washers, 3 pcs xx1000001393





321

4 Repair


Continued

11

Action Note

Refit the bottom plate underneath the robot base by pushing it into the groove and fitting the attachment screw.

If removed, also refit the rear connector plate.

1 screw: M6 x 8.

Note

Direct the bends on the bottom plate downwards!

12

CAUTION

The base and axis 1 gearbox weighs 310 kg

+ 200 kg.


xx0300000612

• A: Bottom plate

• B: Rear connector plate

• C: Attachment screw

• D: Groove

13

14

15

Lift the robot base and gearbox 1 and remove the base and gear support.

Secure the base to the mounting site.

See

Orienting and securing the robot on page 81

.

Refit the complete arm system.

Detailed in section

Refitting, arm system on page 213

.

CAUTION

This is a complex task to be performed with utmost care in order to avoid injury or damage!

16 Perform a leak-down test.

17

18



See section

Performing a leak-down test on page 174 .

See


.





.



.


322




4 Repair


Continued

Action

19

DANGER



.

Note




323

4 Repair

4.7.2 Replacing the gearbox, axes 2- 3

4.7.2 Replacing the gearbox, axes 2- 3

Location of gearbox, axes 2-3

The axis-2 and axis-3 gearboxes are located on either side of the frame as shown in the figure.

The figure shows robot variant IRB 6660 - 130/3.1. The location of the gearboxes is the same on all variants.

xx0700000063

A

B

C

Gearbox, axis 2

Gearbox, axis 3

Hole for lockscrew


Equipment, etc.

Gearbox, axes 2-3

Sealing axes 2-3

O-ring

Lock screw M16x55

Screw M12x50

Screw M12x100

Guide pins M12

Lifting accessory

Guide sleeves

-

-

-

Art.no


•


Note

-

3HAC022379-001

-

3HAB3772-127

3HAC14628-1/2

Always replace.

Replace if damaged.

Use to lock the lower arm.

2 pcs. Use to unload the balancing device.

2 pcs, must have full thread. Use to press the gearbox free from the frame.

Use guide pins in pairs.

Roundsling and a rotating lifting point.

Lifting capacity: 100 kg. Used to lift the gearbox.

Use to keep the sealing in place.





4 Repair


Continued

Equipment, etc.

Grease

Bearing grease

Art.no

3HAB3537-1

Rust preventive

Standard toolkit


3HAC034903-001

Note

Use to lubricate surfaces on the gearbox for easier assembly.

Shell Alvania W R2

Option Foundry Plus








1

Action




Note







Axis Calibration in


.






Removal, axis-2 / axis-3 gearbox

Use this procedure to remove the axis-2 or axis-3 gearbox.

Note

Do not replace both gearboxes at the same time, unless the complete arm system is already removed!




325


4 Repair


Continued

1

2

3

Action Note


When removing axis 2 gearbox: Run the axis 2 to -42° and all other axes to 0° (calibration position).

When removing axis 3 gearbox: Run the axis 2 to -40°, axis 3 to +15° and all other axes to 0°.

When removing axis 2 gearbox: Remove all screws in the lower screw area on the inside of the lower arm (7 pcs M12, 2 pcs

M16). See figure.

When removing axis 3 gearbox: Remove all screws in the upper front screw area and three screws in the upper back area.

Axis 2: xx1100000623

Axis 3:

4 Run axis 2 to 0°.

xx1100000624


326




4 Repair


Continued

5

Action

Fit the lock screw in the lower arm to secure axis 2.

Note

CAUTION

Tighten by hand!

6

7

8

9

10

Secure the weight of the upper arm with roundslings in an overhead crane.

Raise the lifting equipment to take the weight of the upper arm.

Release the brakes of axis 2 to rest the weight of the axis against the lock screw.

Release the brakes of axis 3 to rest the weight of the axis by the roundslings and overhead crane.

Remove the two plastic screws in the upper end of the balancing device.

Note

Keep the plastic screws. They will be refitted later.

xx1000001101 xx1000001111





327

4 Repair


Continued

11

Action Note

Insert two screws, M12x50 in the holes to neutralize the spring force. Screw in the screws until they have proper contact with the cylinder inside.

The length of the cylinder is now locked and the balancing device is unloaded. It should now be possible to easily rotate the balancing device.

See the previous figure!

12

DANGER

Turn off all:




13 Drain the gearbox.

Detailed in section

Draining, axes 2 and 3 on page 151

.

Note

Time-consuming activity!

14

15

16

Remove the motor cables of axis-2 or axis-

3 motor, depending on which gearbox is being removed. Protect the cables from getting damaged and from oil spill.

Remove one gearbox at a time!

Remove the axis-2 or axis-3 motor, depending on which gearbox is being removed.

Detailed in section

Replacing motors, axes

2 and 3 on page 281

17 Remove all remaining attachment screws that secure the gearbox to the lower arm system.

Axis 2: M16 and M12.

Axis 3: M12.


328 xx1000001405




4 Repair


Continued

18

Action

Remove the gearbox cover by removing its attachment screws.

Note xx1200000628

19 Remove two opposite screws of the attachment screws that hold the gearbox and replace them with two guide pins.

Note


20

21

Remove the remaining attachment screws.

Fit the lifting accessory to the gearbox.



.

22

CAUTION



23 If required, apply two screws, M12x100 to the holes in the gearbox, in order to press it free. (The screws need to have a full thread.)

24

CAUTION

When the gearbox comes free from the frame and comes off the guide pins it will tilt and there is a risk of damage to the gearbox surfaces! Be aware of this and remove the gearbox carefully!





329

4 Repair


Continued

25

Action

Remove the gearbox axis 2-3 using an overhead crane or similar, with guidance from the fitted guide pins.

Note

26 Remove the sealing from the lower arm and clean it.

Note

The sealing can hang onto the gearbox, sticking to the oil.

xx1200000629 xx1200000630


330




4 Repair


Continued

Refitting, axis-2 / axis-3 gearbox

Use this procedure to refit the axes-2 or axis-3 gearbox.

Note

1

Action

Make sure that the o-ring is fitted to the gearbox. Lightly lubricate it with grease .

2 Fit two guide pins in the frame.

Use two of the attachment holes for the screws that hold the gearbox.

3

CAUTION

The gearbox weighs 69 kg! All lifting equipment used must be sized accordingly!

xx1000001404

Specified in


.

4 Fit the lifting accessory to the gearbox and lift it with an overhead crane.

Specified in


.





331

4 Repair


Continued

5

Action Note

Fit a new sealing to the gearbox and secure it to the gearbox by using two guide sleeves .

When refitting axis 2 gearbox: Insert the guide sleeves in the two middle holes of the upper screw areas.

When refitting axis 3 gearbox: Insert one guide sleeve in the middle screw hole in the upper back area and one guide sleeve in the middle screw hole in the the lower area.



Axis 2: xx1100000621

Axis 3:

6 Foundry Plus:

Apply bearing grease on the highlighted areas on both sides of the sealing.

Note

Do not apply grease closer than 20 mm from the edge of the holes in the sealing.

xx1100000622 xx1400000993


332




4 Repair


Continued

Action

Foundry Plus:

Apply rust preventive on the highlighted area.

Note xx1400001132

7

8

Lubricate necessary surfaces of the gearbox with grease in order to make it easier to insert the gearbox into the frame.

Specified in


.

Put the gearbox onto the guide pins and slide it carefully into place in the frame.

Note

Check that the sealing is in place during the procedure.

xx1000001406

9

10

11

12

Use a crank to move the gears in order to find the holes for the attachment screws.

Secure the gearbox to the lower arm with the attachment screws and washers in two of the screw areas (the third is not reachable at this point). Do not remove the guide sleeves yet.

Axis 2

M12x60 quality 12.9 Gleitmo (6+6 pcs)

• Tightening torque: 120 Nm.

M16x90 quality 12.9 Gleitmo (2+2 pcs)


Axis 3

M12x60 quality 12.9 Gleitmo


Remove the two guide sleeves and replace them with the two remaining M12 screws.

M12x60 quality 12.9 Gleitmo (1+1 pc)


Secure the gearbox to the frame.

M12, quality 8.8-A2F





333


4 Repair


Continued

13

14

15

Action Note

Clean the gearbox of residual grease.

Apply locking liquid in the attachment holes for the gearbox cover.

Loctite 243.

Fit the o-ring in the cover.

xx1000001407

16 Refit the cover with its attachment screws and washers.

M8x35 quality 8.8-A2F (12 pcs)


Note

Fit the cover so that the arrow on the cover points upwards!

17 Refit the motors axes 2-3 .

18 Perform a leakdown test.


334


xx1000001408

See


See


.



4 Repair


Continued

19

20

Action

Refill the gearbox axes 2-3 with oil.

Remove the screws that unload the balancing device and put back the plastic screws.

Note

See

Filling, axes 2 and 3 on page 151

xx1000001111

21

22

23

Remove the lock screw from the lower arm.

Run the axes 2 and 3 to a position where the remaining screws in the lower arm can be fitted.

Axis 2

M12x60 quality 12.9 Gleitmo (6 pcs)


M16x90 quality 12.9 Gleitmo (2 pcs)


Axis 3

M12x60 quality 12.9 Gleitmo








24

DANGER






335

4 Repair

4.7.3 Replacement of gearbox, axis 6

4.7.3 Replacement of gearbox, axis 6


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

The figure shows the motor for robot variant IRB 6660 - 130/3.1 (with cooling elements).

xx0700000165

F

G

D

E

A

B

C

Strap

Gearbox, axis 6

Attachment screws and washers, gearbox (18 pcs)

Attachment screws and washers, turning disk (12 pcs)

Oil plug, draining

Oil plug, filling

Cooling elements


Equipment, etc.

Gearbox

Washers

O-ring

O-ring

O-ring

Article number



.

3HAA1001-172

3HAB3772-57

3HAB3772-64

3HAB3772-61

Note

Includes o-ring

Not included in gearbox!

Replace when damaged.

164.7x3.53

Must be replaced when reassembling gearbox.

150.0x2.0


12 pcs, 13.1x1.6






4 Repair


Continued

Equipment, etc.

Grease

Flange sealant

Standard toolkit -

Article number

3HAB3537-1

12340011-116

Calibration Pendulum toolkit 3HAC15716-1

Calibration tool box, Axis

Calibration

3HAC055412-001

Note


Loctite 574












1

Action




Note







Axis Calibration in


.










337

4 Repair


Continued

Removal, gearbox

The procedure below details how to remove gearbox, axis 6.

1

Action


Note

2

DANGER

Turn off all:





3

4

5

6

Drain the oil from gearbox, axis 6.

Remove the turning disc .



.


Removing, turning disk on page 218

.

Remove the gearbox by unscrewing its attachment screws .

Shown in the figure


.

If required, apply M8 screws to the holes shown in the figure beside to press the gearbox out.

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


338


xx1400001123



4 Repair


Continued

7

Action

Remove the gearbox axis 6 by lifting it out carefully.

Note

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:





2 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.


Manually releasing the brakes on page 73

.

Foundry Plus:



3HAC028197-001 Revision: S xx1400001122


339


4 Repair


Continued

5

Action

Insert the gearbox, axis 6 into the wrist unit.

6 Secure the gearbox with the attachment screws and washers.

7

8

9

10

Refit the turning disc

Perform a

.

leak-down test



.

Note



.

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 219 .


Performing a leakdown test on page 174 .


Changing oil, axis-

6 gearbox on page 159

.






.

11

DANGER



.

340




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

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.

Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant.

If no data is found related to standard calibration, Calibration Pendulum is used as default.


342




5 Calibration

5.1.2 Calibration methods

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 6660 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.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute

Accuracy calibration is used as a TCP calibration. The CalibWare tool guides through the calibration process and calculates new compensation parameters.

This is further detailed in the Application manual - CalibWare Field 5.0

.

If a service operation is done to a robot with the option Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance.

For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in the section


.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum , which describes the method and the different routines further.




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.

344




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 6660

The figure shows robot variant IRB 6660 - 130/3.1 but the position of the marks are the same on all IRB 6660 robot variants.

xx0700000148

A

B

Synchronization plate, axis 1

Synchronization tab on robot





345

5 Calibration

5.2.1 Synchronization marks and synchronization position for axes

Continued

C

D

E

F

G

Synchronization mark, axis 2





346




5 Calibration

5.2.2 Calibration movement directions for all axes

5.2.2 Calibration movement directions for all axes

Overview

When calibrating, the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on. Positive directions are shown in the graphic below.

Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below.

Manual movement directions, 6 axes

Note!

The graphic shows an IRB 7600. The positive direction is the same for all

6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction!

xx0200000089




347

5 Calibration

5.3 Updating revolution counters

5.3 Updating revolution counters

Introduction

This section describes how to do a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.

1

2

3

Action Note

Select axis-by-axis motion mode.

Jog the manipulator to align the synchronization marks.

See

Synchronization marks and synchronization position for axes on page 345 .

When all axes are positioned, update the revolution counter.

Step 2 - Updating the revolution counter with the FlexPendant on page 349 .

Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important to make sure that axes 4 and 6 of the following mentioned manipulators are positioned correctly. The axes can be calibrated at the wrong turn, resulting in an incorrect manipulator calibration.

Make sure the axes are positioned according to the correct calibration values, not only according to the synchronization marks. The correct values are found on a label, located either on the lower arm, underneath the flange plate on the base or on the frame.

At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated.

If one of the following mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration position will be lost due to non-integer gear ratio. This affects the following manipulators:

Manipulator variant

IRB 6660

Axis 4

Yes

Axis 6

Yes

If the synchronization marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the synchronization marks again (try both directions, if needed).


348




5 Calibration


Continued

Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).

1

Action

On the ABB menu, tap Calibration .

xx1500000942

2 All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.


3HAC028197-001 Revision: S xx1500000943



349

5 Calibration


Continued

3

Action

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) .

xx1500000944

4 A screen is displayed, tap Rev. Counters .

en0400000771


350




5 Calibration


Continued

5

6

7

Action

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 365

.




351

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.





5 Calibration

5.4.1 Description of Axis Calibration

Continued

Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the beginning of the procedure on the FlexPendant.

Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling or equipment fitted to the robot.

Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the robot is dressed with tools, process cabling or other equipment.

If calibrating the robot with reference calibration there must be reference values created before repair is made to the robot, if values are not already available.

Creating new values requires possibility to move the robot. The reference values contain positions of all axes, torque of axes and technical data about the tool installed. A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.


When reference calibration is performed, the robot is restored to the status given by the reference values.

Note

Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Validation

When calibrating the robot with the reference calibration routine, the robot must be dressed with the same tools, process cabling and any other equipment as when the reference values were created.

In the mentioned routines, it is also possible to validate the calibration data.

Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to its calibration position during the calibration procedure.

In order for the axis to be able to be moved to calibration position, or in order for getting proper access to the calibration bushing, other axes might need to be jogged to positions different from 0 degrees. Information about which axes are allowed to be jogged will be given on the FlexPendant. These axes are marked with Unrestricted in the FlexPendant window.




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


354




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

This section shows how the robot is equipped with items for installation of calibration tools for Axis Calibration (fixed calibration pins and/or bushings).

Installed calibration tools are not shown.

A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows.

Spare parts xx1500003256

The fixed calibration pin for axis 1 is installed on a removable tower. The tower will need to be removed if electronic position switches are fitted to the robot. Keep the tower in a safe location for future recalibration needs and mark it with robot serial number to ensure that the correct one is refitted.

When calibration is not being performed, a protective cover and an o-ring should always be installed on the fixed calibration pin as well as a protective plug, included a sealing, in the bushing. Replace damaged parts with new, if needed.

Spare part

Protection cover and plug set

Article number

3HAC056806-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.

356




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 353

.

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.




357


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


358




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 357 .

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 .




359


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 358

.

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 347

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 .


360




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 .





361

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.

362




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.




363

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 365 .

Adjust the synchronization marks when the calibration is done, if necessary.


Synchronization marks and synchronization position for axes on page 345 .

Write down the values on a new label and stick it on top of the calibration label.

xx

Remove any calibration equipment from the robot.

364




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






6 Decommissioning

6.1 Introduction



Introduction

This section contains information to consider when taking a product, robot or controller, out of operation.

It deals with how to handle potentially dangerous components and potentially hazardous materials.

General

All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit are installed.

If the robot or the control unit is partially or completely disposed of, the various parts must be grouped together according to their nature (which is all iron together and all plastic together), and disposed of accordingly. These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed.




367


6.2 Environmental information

6.2 Environmental information

Symbol

The following symbol indicates that the product must not be disposed of as common garbage. Handle each product according to local regulations for the respective content (see table below).

xx1800000058

Hazardous material

The table specifies some of the materials in the product and their respective use throughout the product.

Dispose components properly according to local regulations to prevent health or environmental hazards.

Material

Batteries, NiCad or Lithium

Copper

Cast iron/nodular iron

Steel

Neodymium

Plastic/rubber

Oil, grease

Aluminium

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

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.

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.





6.3 Scrapping of robot

6.3 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries:

• Always remove all batteries. If a battery is exposed to heat, for example from a blow torch, it will explode.

• Always remove all oil/grease in gearboxes. If exposed to heat, for example from a blow torch, the oil/grease will catch fire.

• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed.




369


6.4 Decommissioning of balancing device

6.4 Decommissioning of balancing device

Note

This section is not applicable to robot variant IRB 6660 - 205/1.9.

General

There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.

The device must be dismantled by a decommissioning company.


Equipment

Standard toolkit -

Art. no.

Protective clothing that also covers face and hands

Cutting torch with a long shaft

-

-


Note



.

Must protect against spatter of sparks and flames.

For opening housing and cutting coils.

The long shaft is a safety requirement.


DANGER

Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!

Action on field, decommissioning

The procedure below details the actions to perform on field, when the balancing device is to be decommissioned.

1

2

Action Note

Remove the balancing device from the robot.

Detailed in section


.

Send the device to a decommissioning company.

Make sure the decommissioning company is well informed about the stored energy built up by high tensioned compression springs and that the device contains some grease.

The following procedure contains useful information about decommissioning.


370






Continued

Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact

ABB Robotics for further consultation.

Action Note

1

DANGER

There is stored energy built up by high tensioned compression springs inside the balancing device! When a coil is cut the released tension creates a spatter of sparks and flames.

The working area must be free of flammable materials. Position the balancing device so that the spatter will be directed away from personnel.

2 Clamp the device at the working location.

Place the device at ground level so that the hole and spring coils are cut from a more safe distance.

3

DANGER

The hole must be cut as specified in the figure. Pieces can be ejected from the cylinder at high speed if the hole is cut larger than specified!

4 Cut a hole in the housing as shown in the figure.

Use a cutting torch with a long shaft.

The measurements shown below are maximum values!

xx0700000155





371



Continued

Action

5

DANGER

There is stored energy built up by high tensioned compression springs inside the balancing device! When a coil is cut the released tension creates a spatter of sparks and flames.

The working area must be free of flammable materials. Position the balancing device so that the spatter will be directed away from personnel.

Note

6

7

Cut the coils of the springs inside the housing as specified below:

• Outer spring: cut at least five coils!

• Middle spring: cut at least four coils!

• Inner spring: cut at least four coils!

Use a cutting torch with a long shaft.

Double-check the number of coils cut and make sure all the tension in the springs are removed.

372




7 Reference information

7.1 Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.




373


7.2 Applicable standards

7.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased out or replaced standards are removed from the list when needed.

Standards, EN ISO

The product is designed in accordance with the requirements of:

Standard

EN ISO 12100:2010

EN ISO 13849-1:2015

EN ISO 13850:2015

EN ISO 10218-1:2011

ISO 9787:2013

ISO 9283:1998

Description

Safety of machinery - General principles for design - Risk assessment and risk reduction

Safety of machinery, safety related parts of control systems -

Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Robots for industrial environments - Safety requirements -Part

1 Robot

Robots and robotic devices -- Coordinate systems and motion nomenclatures

Manipulating industrial robots, performance criteria, and related test methods

Classification of air cleanliness

Ergonomics of the thermal environment - Part 1

EMC, Generic emission

EN ISO 14644-1:2015 i

EN ISO 13732-1:2008

EN 61000-6-4:2007 +

A1:2011

IEC 61000-6-4:2006 +

A1:2010

(option 129-1)

EN 61000-6-2:2005

IEC 61000-6-2:2005

EN IEC 60974-1:2012 ii

EN IEC 60974-10:2014

ii

EMC, Generic immunity

Arc welding equipment - Part 1: Welding power sources

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part

1 General requirements i ii

IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)

Only robots with protection Clean Room.

Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard

EN 614-1:2006 + A1:2009

EN 574:1996 + A1:2008

Description

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles

Safety of machinery - Two-hand control devices - Functional aspects - Principles for design






7.2 Applicable standards

Continued

Other standards

Standard

ANSI/RIA R15.06

ANSI/UL 1740

CAN/CSA Z 434-14

Description

Safety requirements for industrial robots and robot systems

Safety standard for robots and robotic equipment

Industrial robots and robot Systems - General safety requirements




375


7.3 Unit conversion

7.3 Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity

Length

Weight

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 g

1 bar

1 N

1 Nm

1 L

3.28 ft.

2.21 lb.

0.035 ounces

100 kPa

0.225 lbf

0.738 lbf-ft

0.264 US gal

39.37 in

14.5 psi

376





7.4 Screw joints

7.4 Screw joints

General

This section describes how to tighten the various types of screw joints on the IRB

6660.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints.

It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed. Using other types of screws will void any warranty and may potentially cause serious damage or injury.

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1 Apply lubricant to the screw thread.

2 Apply lubricant between the plain washer and screw head.

3 Screw dimensions of M8 or larger must be tightened with a torque wrench.

Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.

Lubricant

Molycote 1000 (molybdenum disulphide grease)

Article number

3HAC042472-001

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the following tables. Any special torques are specified in the repair, maintenance or installation procedure descriptions.

Any special torque specified overrides the standard torque!

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.




377



7.4 Screw joints

Continued

• Always tighten the joint by hand, and never use pneumatic tools.

• Use the correct tightening technique , that is do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10% !

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Note

A special torque specified in the repair, maintenance or installation procedure overrides the standard torque.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with allen head screws.

Note


Dimension

M5

M6

M8

M10

M12

M16

M20

M24

10

24

47

82

Tightening torque (Nm)

Class 8.8, oil-lubricated

Tightening torque (Nm) Tightening torque (Nm)



6 -

-

34

67

115

-

40

80

140

200

400

680

290

560

960

340

670

1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head screws.

Note


Dimension Tightening torque (Nm)

Class 10.9, lubricated i

28 M8


378


Class 12.9, lubricated

i

35





7.4 Screw joints

Continued

Dimension Tightening torque (Nm)

Class 10.9, lubricated i


Class 12.9, lubricated

i

M10

M12

M16

55

96

235

70

120

280

M20 460 550 i

M24 790 950

Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass .

Note


1/8

1/4

3/8

1/2

3/4

Dimension

15

20

40

70

Tightening torque Nm -

Nominal


Min.


Max.

12 8 15

10

15

30

55

20

25

50

90




379


7.5 Weight specifications

7.5 Weight specifications

Definition

In installation, repair, and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way.

To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

Example

Following is an example of a weight specification in a procedure:

Action Note

CAUTION

The robot weighs 1950 kg.

All lifting accessories used must be sized accordingly.

380





7.6 Standard tools

7.6 Standard tools

General

All service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standard toolkit and defined in the following table.

This way, the tools required are the sum of the standard toolkit and any tools listed in the instruction.

Contents, standard toolkit

1

1

1

1

1

1

1

2

1

1

1

1

Qty Tool

Ring-open-end spanner 8-19 mm

Socket head cap 5-17 mm

Torx socket no: 20-60

Box spanner set

Rem.

Torque wrench 10-100 Nm

Torque wrench 75-400 Nm

Ratchet head for torque wrench 1/2

Hexagon-headed screw M10x100

Hex bit socket head cap no. 14 socket 40 mm L=100 mm

Hex bit socket head cap no. 14 socket 40 mm L=20 mm To be shortened to 12 mm

Hex bit socket head cap no. 6 socket 40 mm L=145 mm

Hex bit socket head cap no. 6 socket 40mm bit L=220 mm




381


7.7 Special tools

7.7 Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section


, and of special tools, listed directly in the instructions and also gathered in this section.

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.

Calibration tool box, Axis Calibration

3HAC055412-

001

Note




382





7.7 Special tools

Continued

Oil exchange equipment

The following table specifies the recommended equipment for oil exchange.

Description


Art. no.

3HAC021745-001

Note

Includes:

• Vacuum pump with regulator, hose and coupling

• Couplings and adapters

• Pump (manual) with hose and coupling

• Graduated measuring glass

• Oil gun

• User instructions.

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



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

2

1

2

2

1

2

Qty

1

2

Art. no.

3HAC12342-1

3HAC15520-1

3HAC15520-2

3HAC15521-1

3HAC15521-2

3HAC14459-1

3HAC15534-1

3HAC14972-1

Fits motors, axes 6.

-

Fits motors axes 1, 2 and 3.

3HAC17105-1

Lifting tools

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.

Article no.

Description Qty

Hoisting block 1

Lifting chain (used together with the hoisting block)

1

Support, base and gearbox axis 1

Lifting tool, gearbox axis 1

1

1

3HAC15535-1

3HAC15556-1




383



7.7 Special tools

Continued

Description

Lifting eye (used together with lifting tool

3HAC15556-1)

Lifting tool, motor

Lifting tool, gearbox axes 2-3

Lifting tool, frame

Lifting tool. complete robot

Qty

1

1

1

1

Lifting tool, parallel arm

Lifting tool, wrist unit

Lifting tool, base

Standard toolkit (content described in section


)

1

1

1

1

Special tools

Article no.

3HAC025333-005

3HAC14586-1

3HAC023240-001

3HAC023308-001

3HAC15607-1

(User instruction 3HAC15971-1)

3HAC023098-001

-

3HAC13605-1

3HAC14868-1

The following table specifies the special tools required during several of the service procedures. The tools may be ordered separately and are also specified directly in concerned instructions.

Qty Description

KM8 socket

KM10 socket

Pinion crank

Pressing, lower arm/balancing weight

Pressing, upper arm

Pressing, tie rod

Auxiliary shaft, long

Auxiliary shaft, short

Support shaft/bearing race

Tool for lubrication

Adapter for shaft axis 3

Guide sleeves

Article no.

Standard

Standard

3HAC023132-001

3HAC023092-001

3HAC023084-001

3HAC5021-1

3HAC5275-1

3HAC5276-1

3HAC5281-1

3HAC5222-1

3HAC023916-001

3HAC14446-1

384





7.8 Lifting accessories and lifting instructions

7.8 Lifting accessories and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure.

The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.

This implies that the instructions delivered with the lifting accessories should be stored for later reference.




385


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

.




387


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 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


389



9.1 Circuit diagrams

Continued

Product


Circuit diagram - IRB 6620 / IRB 6620LX


Circuit diagram - IRB 6650S




Circuit diagram - Product.ProductName

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

390




Index

Index

A

Absolute Accuracy, calibration, 343

additional mechanical stop location, 138

aluminum

disposal, 368

ambient humidity

operation, 53 storage, 53

ambient temperature


assembly instructions, 49

assessment of hazards and risks, 20

Axis Calibration, 352

calibration tool

article number, 354, 357

examining, 354

installation position, 356

overview of method, 352

procedure on FlexPendant, 357

protective cover and protection plug, 356–357

B balancing device

inspecting bearing, 126 inspecting piston rod guide ring, 126

lubricating bearing, 166 lubricating piston rod, 166

base plate

guide pins, 76 securing, 76

batteries

disposal, 368

handling, 37

battery

replacing, 162, 259

battery pack

replacing, interval, 112

battery shutdown

service routine, 162, 259

bearing,balancing device, 126

bearing, balancing device, 166

brake release, 73

brake release board, replacement, 262

brakes

testing function, 36

buttons for brake release, 73

C

cabinet lock, 25, 31

cabling, robot, 104

cabling axis 5, replacement, 204

cabling between robot and controller, 104

calibrating

robot, 352

roughly, 348

calibrating robot, 352

calibration

Absolute Accuracy type, 342

rough, 348

standard type, 342

verification, 364

when to calibrate, 344

calibration, Absolute Accuracy, 343




calibration manuals, 343

calibration marks, 345

calibration position

jogging to, 365

scales, 345 calibration scales, 345

CalibWare, 342

carbon dioxide extinguisher, 22

cast iron

disposal, 368

changing oil

axis 1, 146

axis 2, 149 axis 3, 149

cleaning, 169

climbing on robot, 25

Cold environments, 107

complete arm system, replacement, 207

connecting the robot and controller, cabling, 104

connection

external safety devices, 26

copper

disposal, 368

D

damage to additional mechanical stop, 138

damage to mechanical stop, 136

danger levels, 40

dimensions

frame, 86

turning disk, 87

upper arm, 84

direction of axes, 347

E

enabling device, 30

environmental information, 368

EPS, 103

equipment on robot, 84

ESD

damage elimination, 33 sensitive equipment, 33

expected life, 113

extended working range, axis 1, 103

external safety devices, 26

extra equipment

fastener quality, 87

frame, 86

robot, 84

turning disk, 87

upper arm, 84

F

fastener quality for extra equipment, 87

fire extinguishing, 22

fitting equipment on robot, 84

FlexPendant

jogging to calibration position, 365

MoveAbsJ instruction, 365

updating revolution counters, 349

fork lift, 60

foundation

requirements, 52

frame

dimensions, 86

391

Index

G gearbox

oil change axis 1, 146

oil change axis 2, 149 oil change axis 3, 149

gearbox axis 1, replacement, 311

gearbox axis 6, replacement, 336

gearboxes

location of, 144

grease

disposal, 368

guide pins, base plate, 76

guide ring, piston rod, 126

H hanging

installed hanging, 25

hazardous material, 368

height

installed at a height, 25

hold-to-run, 30

HRA, 20

humidity


I

information labels location, 134

inspecting

additional mechanical stop, 138

balancing device bearing, 126 balancing device piston rod guide ring, 126

information labels, 134

mechanical stop, 136

inspecting oil levels

axes 2-3, 116

axis-6, 123

axis-5, 121

axis-4, 119

axis-1, 114

installation

mechanical stop axis 1, 101

installing equipment on robot, 84

instructions for assembly, 49

integrator responsibility, 19

intervals for maintenance, 111

L labels

robot, 42

leak-down test, 174

lifting accessory, 380

lifting robot

with fork lift, 60

with lifting slings, 69

with roundslings, 66

lifting slings, robot, 69

limitation of liability, 19

Lithium

disposal, 368

loads on foundation, 51

lubricating

balancing device bearing, 166 balancing device piston rod, 166

lubrication

amount in gearboxes, 144 type of lubrication, 144

392


M

maintenance schedule, 111

manually releasing brakes, 73

mechanical stop

axis 1, 101

mechanical stop location, 136

motion of axes, 57

motor axis 4, replacement, 292



MoveAbsJ instruction, 365

N

nation specific regulations, 19

negative directions, axes, 347

neodymium

disposal, 368

NiCad

disposal, 368

nodular iron

disposal, 368

O oil

amount in gearboxes, 144

disposal, 368

type of oil, 144

oil change

axis 1, 146

axis 2, 149 axis 3, 149

safety risks, 38

oil level

gearbox axes 2-3, 116

gearbox axis-6, 123

gearbox axis-5, 121

gearbox axis-4, 119

gearbox axis-1, 114

operating conditions, 53

P pedestal

installed on pedestal, 25

piston rod, balancing device, 166

piston rod guide ring inspectiong, 126

plastic

disposal, 368

positive directions, axes, 347

product standards, 374

protection classes, 53 protection type, 53

protective equipment, 26 protective wear, 26

R

range of movement, 57

region specific regulations, 19

release brakes, 23

replacement

brake release board, 262

cabling axis 5, 204

complete arm system, 207

gearbox axis 1, 311

gearbox axis 6, 336

motor axis 4, 292

motor axis 5, 297

motor axis 6, 303



Index

turning disk, 217

wrist unit, 221

requirements on foundation, 52

responsibility and validity, 19

restricting

working range axis 1, 101, 103

revolution counters

storing on FlexPendant, 349

updating, 348

risk of tipping, 58

robot

labels, 42

protection class, 53 protection types, 53

symbols, 42

rubber

disposal, 368

S safety

brake testing, 36

ESD, 33

fire extinguishing, 22

moving robots, 27

release robot axes, 23

signal lamp, 99

signals, 40 signals in manual, 40 symbols, 40

symbols on robot, 42

test run, 28

working range, 29

safety equipment

mechanical stop, 101

signal lamp, 142

safety fence, 20

safety risk

electric parts, 31

hot parts, 34

hydraulic system, 35

installation, 25

oil change, 38

operational disturbance, 25

pneumatic system, 35

service work, 25

voltage, 31

safety signals

in manual, 40

safety standards, 374

safety zones, 20

scales on robot, 345

schedule for maintenance, 111

screw joints, 377

securing

base plate, 76

securing, robot, 81 securing the robot to foundation, attachment screws, 81

signal lamp, 99

signals

safety, 40

SMB

replacing, 259

SMB battery

extension of lifetime, 162, 259 replacing, 162, 259

special tools, 382

speed

adjusting, 107

stability, 58

standards, 374

ANSI, 375

CAN, 375

EN, 374

EN IEC, 374

EN ISO, 374

start of robot in cold environments, 107

steel

disposal, 368

storage conditions, 53

symbols

safety, 40

synchronization position, 348

sync marks, 345

system integrator requirements, 19

T temperatures


testing

brakes, 36

three-position enabling device, 30

tools

Axis Calibration, 382

Calibration Pendulum, 382 for service, 382

oil exchange equipment, 383

torques on foundation, 51

troubleshooting

oil spills, 169

turning disk dimensions, 87

turning disk replacement, 217

type of motion, 57

U

updating revolution counters, 348

upper arm

dimensions, 84

V

validity and responsibility, 19

velocity

adjusting, 107

verifying calibration, 364

W

weight, 50

base plate, 75, 80

gearbox, 331

motor, 277–278

robot, 65–66, 72, 241, 246–249, 255, 257, 269, 271,

315, 317, 319, 322, 329, 380

upper arm, 233–234

wrist unit, 224–225

working range, 54

restricting axis 1, 101

wrist unit, replacement, 221

Z zero position

checking, 365



393


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 6660, IRB 6660 - 100/3.3 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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