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ABB IRB 6620, Product Manual

Product Specification: The ABB IRB 6620 is an advanced industrial robot designed to streamline complex manufacturing processes. Ensure optimal efficiency and productivity with this versatile robot by downloading its user manual for free from our website. Explore in-depth instructions that guarantee seamless operations and superior performance.

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Table of contents

9

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

14

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

16

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

17

1

Safety

17

1.1

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

17

1.1.1

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

20

1.1.2

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

21

1.2

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

21

1.2.1

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

22

1.2.2

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

23

1.2.3

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

24

1.3

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

24

1.3.1

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

26

1.3.2

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

27

1.3.3

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

28

1.3.4

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

29

1.3.5

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

30

1.3.6

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

32

1.3.7

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

33

1.3.8

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

34

1.3.9

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

35

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

36

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

37

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

39

1.4

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

39

1.4.1

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

41

1.4.2

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

47

2

Installation and commissioning

47

2.1

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

48

2.2

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

54

2.3

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

57

2.4

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

57

2.4.1

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

61

2.4.2

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

65

2.4.3

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

66

2.5

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

66

2.5.1

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

66

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

69

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

72

2.5.2

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

77

2.5.3

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

79

2.5.4

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

81

2.5.5

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

82

2.5.6

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

87

2.5.7

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

91

2.5.8

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

96

2.5.9

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

104

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

105

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

106

2.6

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

106

2.6.1

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

107

2.6.2

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

109

2.6.3

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

Product manual - IRB 6620

5

3HAC027151-001 Revision: T

© Copyright 2006-2018 ABB. All rights reserved.

Table of contents

Summary of Contents for IRB 6620

Page 1: ...ROBOTICS Product manual IRB 6620 ...

Page 2: ...Trace back information Workspace R18 1 version a9 Checked in 2018 03 22 Skribenta version 5 2 025 ...

Page 3: ...Product manual IRB 6620 150 2 2 IRC5 Document ID 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved ...

Page 4: ...BB 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 AB...

Page 5: ... manual 41 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Robot transportation precautions 54 2 3 Securing the robot with a transport support 57 2 4 Unpacking 57 2 4 1 Pre installation procedure 61 2 4 2 Working range and type of motion 65 2 4 3 Risk of tipping stability 66 2 5 On site installation 66 2 5 1 Lifting the robot with fork lift acc...

Page 6: ...e 149 3 4 Replacement changing activities 149 3 4 1 Type of lubrication in gearboxes 151 3 4 2 Changing oil axis 1 gearbox 154 3 4 3 Changing oil axis 2 gearbox 157 3 4 4 Changing oil axis 3 gearbox 160 3 4 5 Changing oil axis 4 gearbox 163 3 4 6 Changing oil axis 5 gearbox 166 3 4 7 Changing oil axis 6 gearbox 169 3 4 8 Replacing the SMB battery 173 3 5 Cleaning activities 173 3 5 1 Cleaning the ...

Page 7: ...313 5 3 Updating revolution counters 319 5 4 Calibrating with Axis Calibration method 319 5 4 1 Description of Axis Calibration 322 5 4 2 Calibration tools for Axis Calibration 324 5 4 3 Installation locations for the calibration tools 326 5 4 4 Axis Calibration Running the calibration procedure 332 5 5 Calibrating with Calibration Pendulum method 333 5 6 Verifying the calibration 334 5 7 Checking...

Page 8: ...This page is intentionally left blank ...

Page 9: ...rough before performing any installation or service work on robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Safety Required information about lifting and installation of the robot Installation and commis sioning Step by step procedures that describe how to perform mainten ance of the robot Based on a maintenance...

Page 10: ...50944 001 Operating manual Service Information System 3HAC051016 001 Application manual Additional axes and stand alone controller 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC050948 001 Technical reference manual System parameters 3HAC030421 001 Application manual CalibWare Field 5 0 i This manual contains all safety instructions from the product manuals for the manipula...

Page 11: ...evels for tilted robots see Inspecting the oil level in axis 1 gearbox on page 120 and Inspecting the oil level in axis 2 gearbox on page 122 Corrected item number reference in part list see Spare parts Upper arm in Product manual spare parts IRB 6620 Circuit diagrams are not included in this document but delivered as separate files See Circuit diagram on page 353 List of standards updated see App...

Page 12: ...s Corrected location of label for lifting see Inspecting the information labels on page 137 Spare part number for wrist standard was wrong Has been corrected A new SMB unit and battery is introduced with longer battery lifetime J This revision includes the following updates New instruction for inspection of oil level Added information about risks when scrapping a decommissioned robot see Scrapping...

Page 13: ...rding overhaul in section specification of maintenance intervals Section Start of robot in cold environments on page 114 added Updated information regarding replacement of brake release board Updated information regarding disconnecting and reconnecting battery cable to serial measurement board Definition of reference calibration clarified S Published in release R18 1 The following updates are made...

Page 14: ...erence information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Ap...

Page 15: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 6620 15 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved Product documentation Continued ...

Page 16: ...ompleted 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 Note Illustration Action Art no is...

Page 17: ...arried 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 respo...

Page 18: ...eed 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 sl...

Page 19: ...al parts through welding riveting or drilling of new holes into the castings The strength could be affected CAUTION Ensure that a gripper is prevented from dropping a work piece if such is used Product manual IRB 6620 19 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 1 1 Limitation of liability Continued ...

Page 20: ...view The protective stops and emergency stops are described in the product manual for the controller 20 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 21: ...uishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller Product manual IRB 6620 21 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 22: ... may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot 22 Product m...

Page 23: ...troller before proceeding work Note Switch off all main power switches in a MultiMove system Spot welding cabinet Wait for 5 minutes to let the capacitors discharge after the power has been switched off DANGER Even if the main switch is switched off the capacitors can cause electric shock if not given the time to discharge Product manual IRB 6620 23 3HAC027151 001 Revision T Copyright 2006 2018 AB...

Page 24: ...afety 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 pur...

Page 25: ...fications 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 we...

Page 26: ...y stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to...

Page 27: ...fore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If ...

Page 28: ...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...

Page 29: ...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 pr...

Page 30: ...lated 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...

Page 31: ...e 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 Product manual IRB 6620 31 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 32: ...e Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of ...

Page 33: ... 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 Product manual IRB 6620 33 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 3 8 Ho...

Page 34: ...re 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 a...

Page 35: ...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 Product manual IRB 6620 35 3HAC027151 001 Revision T Cop...

Page 36: ...losion 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 ...

Page 37: ...ion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic re...

Page 38: ... time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct 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 Specified amount de pends on drained vol...

Page 39: ...ccur if the instructions are not followed that can lead to serious injury pos sibly 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 WARNING xx0100000002 Warns for electrical hazards which could result in severe ...

Page 40: ...NOTE xx0100000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 40 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 41: ...lish German and French Symbols on safety labels Description Symbol Warning xx0900000812 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 c...

Page 42: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 42 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights re...

Page 43: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 6620 43 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 44 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...0001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 6620 45 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 46: ...hat this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 46 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

Page 47: ...portant 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 page17 before performing any installation work Note If the IRB 6620 is connected to power always make sure that the robot is connected to protective...

Page 48: ...s strongly recommended by ABB xx0800000030 Always follow these instructions when transporting an ABB robot according to method 1 Always remove the tool before transportation of the robot Always place the robot in the ABB recommended transport position described in section Risk of tipping stability on page 65 Always read and follow the instructions in section Pre installation procedure on page 57 M...

Page 49: ...nded transport position for robot with tool described in sub section Transport position with a transport support on page 51 Always use the recommended transport support described in sub section Recommended transport support on page 52 Continues on next page Product manual IRB 6620 49 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 Robot tr...

Page 50: ...cket head cap screw M10x50 B Threaded bar M10x280 C Nut M10 D Continues on next page 50 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 Robot transportation precautions Continued ...

Page 51: ...e robot with tool must follow these instructions IRB 6620 xx0800000041 Continues on next page Product manual IRB 6620 51 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 Robot transportation precautions Continued ...

Page 52: ...t support when transporting a robot with tool IRB 6620 xx0800000039 Continues on next page 52 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 Robot transportation precautions Continued ...

Page 53: ...IRB 6620 xx0800000038 Product manual IRB 6620 53 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 2 Robot transportation precautions Continued ...

Page 54: ...f the robot must be transported with mounted tools DANGER Releasing the brakes is a hazardous action that may cause injury and damage property It must be done with great care and only when absolutely necessary Continues on next page 54 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 Securing the robot with a transpo...

Page 55: ...er end to the robot using the recommended screw joint A in figure 1 See attachment point for the specific ro bot in the section Transport position with a transport support on page 51 Continues on next page Product manual IRB 6620 55 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 3 Securing the robot with a transport support Continued ...

Page 56: ...port support see the section Manually releasing the brakes on page 79 3 CAUTION Do not attempt to tighten any attachment screws without first releasing the brakes This can seriously damage the robot Tighten all the attachment screws A and B in the figure with the brake release for axis 3 still activated starting with the lower attachment screw 4 Use the brake release for axis 5 and 6 to reach the ...

Page 57: ...uired is suitable to handle the weight of the robot as specified in Weight robot on page 58 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 60 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 60 7 Before taking the robot to its installation ...

Page 58: ...robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz 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 a...

Page 59: ...Requirement Flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from ABB 0 3 mm Flatness of foundation surface 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...

Page 60: ...nance frequencies in the region 10 20 Hz and disturbances in this region will be amplified although somewhat damped by the servo control This might be a problem depending on the requirements from the applications If this is a problem the robot needs to be isolated from the environment Storage conditions robot The table shows the allowed storage conditions for the robot Value Parameter 25 C Minimum...

Page 61: ...e specified at the wrist center dimensions in mm Floor mounted The illustration below shows the unrestricted working range when the robot is floor mounted 854 1473 2204 858 976 2564 xx0600002906 Continues on next page Product manual IRB 6620 61 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Working range and type of motion ...

Page 62: ... when the robot is mounted suspended 854 1473 2204 858 2564 976 xx0600002907 Continues on next page 62 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Working range and type of motion Continued ...

Page 63: ... 1 5 2369 1171 1127 2550 1019 693 B A xx0600002908 Note Maximum tilt angle is 15 A Intersection between base and axis 1 center B Continues on next page Product manual IRB 6620 63 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Working range and type of motion Continued ...

Page 64: ...pack 70 to 115 Arm motion 3 300 to 300 Wrist motion 4 Limitations with dresspack 130 to 130 Bend motion 5 Max 96 revolutions 300 to 300 default Turn motion 6 The default working range can be extended by changing parameter values in the software OptionAdvanced Motion is required 64 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commi...

Page 65: ...is the most stable position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position xx0600002935 WARNING The robot is likely to be mechanically unstable if not secured to the foundation Product manual IRB 6620 65 3HAC027151 001 Revision T Copyright 2006 2018 ABB All r...

Page 66: ...k lift truck Fork lift truck Preparations before fitting the fork lift pockets Note Action DressPack if used can stay fitted as long as the tool fitted on the turning disk is removed Remove any tools fitted on the axis 6 turning disk Note No tool is permitted to be fitted on the robot when lifting the robot with the fork lift accessory 1 xx0600002935 Jog the robot to its shipping position See figu...

Page 67: ...ints on the robot The fork lift accessory is fitted on the robot as shown in the figure xx0600002910 Fork lift pocket A Attachment screw M20x60 quality 8 8 2 pcs x4 B Continues on next page Product manual IRB 6620 67 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 1 Fitting the fork lift accessory Continued ...

Page 68: ... the ro bot with its attachment screws Note Before fitting any attachment screws make sure they are not damaged in any way Replace dam aged screws 1 Verify that all four fork lift pockets are properly secured before lifting 2 68 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 1 Fitting the fork lift accessory Cont...

Page 69: ... truck Lifting the robot with fork lift truck Note Action Note No load is permitted on the robot Make sure that the robot is in shipping position 1 DANGER Make sure that all supplies for electrical power hydraulic pressure and air pres sure are turned off 2 Verify that all four fork lift pockets are properly secured before lifting 3 Continues on next page Product manual IRB 6620 69 3HAC027151 001 ...

Page 70: ...itted If lifting with fewer than four fork lift pockets fitted there is a risk of accidents 4 IRB 6640 Ax2 A x3 Ax5 45 10 80 xx0600003401 IRB 460 xx1000001159 Continues on next page 70 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 2 Lifting the robot with fork lift truck Continued ...

Page 71: ...e present under the suspended load 7 Note Move the robot with low speed Move the robot slowly to its new position 8 Secure the robot to the foundation DANGER Do not power the robot up until it is se cured properly to the foundation 9 Remove the fork lift accessories 10 Product manual IRB 6620 71 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning ...

Page 72: ...ng and turning of the IRB 6620 xx0900000325 Upper lifting beam A Chains B Lifting eye C Lower lifting beam D Lifting hold Left and Right E Continues on next page 72 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Lifting the robot with lifting and turning tool ...

Page 73: ...ure Jog the robot axis to a posi tion suitable for lifting 1 Continues on next page Product manual IRB 6620 73 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Lifting the robot with lifting and turning tool Continued ...

Page 74: ...ng eye upper beam C Attachment bolts in robot base D Distribution beam E Attachment bolts for distribution beam F Lifting chains G Chain block lifting eye H Upper beam I Continues on next page 74 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Lifting the robot with lifting and turning tool Continued ...

Page 75: ... 90Nm Fit the lifting tool 3HAC025792 001 to the robot base using the eight attach ment screws 3 Lift the upper beam using a overhead crane 4 Attach the upper beam to the lower beam using the lifting chains 5 Lift slowly until the chains are tensioned Make sure that no cabling is damaged while lift ing 6 Note Use a suitable chain block for minimum lifting weight 500 kg and with chain length minimu...

Page 76: ...en the floor and robot is at least 350 mm 9 Turn the robot using the chain block 10 If the robot is to be moved to the installation location use a forklift 11 76 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Lifting the robot with lifting and turning tool Continued ...

Page 77: ...lie against sensitive parts for example harness and customer equipment 4 Shown in the figure Attachment points on page 78 When attaching the roundsling A on the up per arm put it in a U shape through the hole in the wrist 5 Shown in the figure Attachment points on page 78 When attaching the roundsling B on the up per arm put it in a sling around the gearbox axis 4 and on the inside of motor axis 4...

Page 78: ...lar with the label attached to the robot s lower arm xx0600002921 Roundsling upper arm 2 5 m A Roundsling upper arm 2 m B Roundsling robot 2 5 m 4 pcs C Lifting eye M20 4 pcs D Holes for lifting eyes in the robotbase Rear holes E 78 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 3 Lifting robot with roundslings Con...

Page 79: ...nit on page 79 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 80 1 DANGER When releasing the holding brakes the robot axes may move ve...

Page 80: ... controller power must be supplied to connector R1 MP on the robot in order to enable the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0600002937 Supply 0V on pin 12 and 24V on pin 11 2 80 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 I...

Page 81: ...g All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 81 Fit lifting eyes in specified holes 2 Fit lifting slings to the eyes and to the lifting accessory CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 Product manual IRB 6620 81 3HAC027151 001 Revision T Copyright 2006 2018 AB...

Page 82: ...3x45º 0 3 Ø 45P7 A A Ø1 5 4x 6 3 4 8 2 1 6 3x45º B B 2 1 3 3x R1 3 x 4 3x 90º C C 4 5 K 7 0 5 0 47 0 25 c 2x R22 5 1 6 D 2 c 5 2 5 º Common Zone E F G H xx1000001053 Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page 82 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installatio...

Page 83: ...for alternative clamping 4x Ø18 A Continues on next page Product manual IRB 6620 83 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 6 Securing the base plate Continued ...

Page 84: ...or leveling bolts in the base plate A A A B B B B xx1500000312 Orienting grooves 3 pcs A Levelling bolts attachment holes 4 pcs B Continues on next page 84 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 6 Securing the base plate Continued ...

Page 85: ...Content is defined in section Standard tools on page 346 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Base plate This section details how to secure the base plate to the foundation Note Action Make sure the foundation is levelled 1 Continues on next pag...

Page 86: ... orienting grooves and leveling bolts on page 84 Fit the base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces ...

Page 87: ...ling screws Note Remove before the robot base is fitted C Base plate attachment screws D 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 M24 x 100 Suitable screws lightly lubricated Quality 8 8 Quality Thickness 4 mm Suitable washer Outer diameter 44 mm Inner diameter 25 mm 725 Nm Tightening torque C...

Page 88: ...bot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 87 Fit the bolts and washers in the base attach ment holes 5 Shown in figure Illustration robot fitted to base plate on page 87 Note Lightly lubricate screws before as sembly Tighten bolts in a criss cross pattern to e...

Page 89: ...ion used when securing the robot R400 4 x 15 4 x 3 7 5 xx0600002932 Continues on next page Product manual IRB 6620 89 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 7 Orienting and securing the robot Continued ...

Page 90: ...tion shows the cross section of the guide sleeve holes xx0600002934 90 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 7 Orienting and securing the robot Continued ...

Page 91: ...e mounting angle must be configured correctly in the system parameters so that the robot system can control the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection Gravity Beta If the ...

Page 92: ...arameter 7 axes high performance motion is set see Technical reference manual System parameters Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage track motion Mounting angles and values The parameter Gravity Beta or Gravity Alpha specifies the mounting angle of the robot in radians It is calculated in the following way Gravity Beta A x 3 141593 180 B ra...

Page 93: ...d mounting mounting angle 15 B Suspended mounting mounting angle 180 C Continues on next page Product manual IRB 6620 93 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 8 Setting the system parameters for a suspended or tilted robot Continued ...

Page 94: ...s 0 0 Floor mounted 1 0 785398 45 Tilted 2 1 570796 90 Wall 3 1 570796 90 Wall 4 Note For suspended robots 180 it is recommended to use Gravity Beta instead of Gravity Alpha Continues on next page 94 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 8 Setting the system parameters for a suspended or tilted robot Conti...

Page 95: ...new value is detailed in Mounting angles and values on page92 The system parameters are described in Technical reference manual System parameters The system parameters are redefined in the Configuration Editor in RobotStudio or on the FlexPendant Product manual IRB 6620 95 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 8 Setting the syste...

Page 96: ...bot must be designed and fitted not to damage the robot and or its parts Illustration fitting of extra equipment on lower arm The illustrations below shows the mounting holes available for fitting extra equipment on the lower arm Make sure not to damage the robot cabling on the lower arm when fitting extra equipment Always use appropriate attachment screws xx0600002940 Continues on next page 96 Pr...

Page 97: ...600002944 Continues on next page Product manual IRB 6620 97 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 9 Fitting equipment on robot Continued ...

Page 98: ... the mounting holes available for fitting extra equipment on the upper arm xx0600002941 Continues on next page 98 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 9 Fitting equipment on robot Continued ...

Page 99: ...600002945 Continues on next page Product manual IRB 6620 99 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 9 Fitting equipment on robot Continued ...

Page 100: ...ilable for fitting extra equipment on the frame are shown below xx0600002947 Continues on next page 100 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 9 Fitting equipment on robot Continued ...

Page 101: ...00002950 Continues on next page Product manual IRB 6620 101 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 9 Fitting equipment on robot Continued ...

Page 102: ...7 Turning disk for robot version IRB6620 150 2 2 Use every other of the bolt holes for six attachment bolts as numbered in the figure Turning disk type 1 Continues on next page 102 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 9 Fitting equipment on robot Continued ...

Page 103: ...sk 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 Product manual IRB 6620 103 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 9 Fitting equipment on robot Continued ...

Page 104: ...robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot 104 P...

Page 105: ...on 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 Product manual IRB 6620 105 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 5 11 Signal lamp option ...

Page 106: ...echanical stop and software Axis 3 hardware mechanical stop and software As a standard configuration axis 1 is allowed to move 170 This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to relevant manuals are included in the installation procedures 106 Product manual IRB 66...

Page 107: ...ctions Mechanical stops axis 1 The illustration shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 xx0600002938 Movable mechanical stop A Attachment screw plus washer M12 x 40 quality 12 9 2 pcs B Fixed mechanical stop C Mechanical stop pin axis 1 D Continues on next page Product manual IRB 6620 107 3HAC027151 001 Revision T Copyright 2006 2...

Page 108: ...to the robot Before entering the robot working area 1 Tightening torque 120 Nm Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 107 2 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limitations system parameter con...

Page 109: ...2973 Mechanical stop pin axis 3 A Attachment screw and washer B Required equipment Note Art no Equipment etc Includes one mechanical stop pin 3HAC025092 001 attachment screw and washer document for Mech stop pin 3HAC025409 001 3HAC025290 003 Mechanical stop set axis 3 Content is defined in section Standard tools on page 346 Standard toolkit Continues on next page Product manual IRB 6620 109 3HAC02...

Page 110: ...ure Mechanical stops axis 3 on page 109 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Note The software working range limitations system parameters must be redefined to correspond to the changes in the mechanic al limitations of the working range 70 90 3 WARNING If the mechanical stop pin is deformed...

Page 111: ...rd Separate instructions for IRB 140 4600 1600 6620 6640 6650S 6660 and 7600 are available in English German French Spanish and Italian and can be found on the DVD delivered with the Cable guard article number 3HAC035933 001 Product manual IRB 6620 111 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 2 Installation and commissioning 2 7 1 Installation of Foundry Plus Cable gua...

Page 112: ...Handles power supply to and control of the external axes motors as well as feedback from the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot...

Page 113: ...diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1500001603 Product manual IRB 6620 113 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rig...

Page 114: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 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 Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

Page 115: ...sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 17 before performing any service work Note If t...

Page 116: ...al 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 ident...

Page 117: ...eaning the IRB 6620 on page 173 Robot Cleaning Every 12 months Oil level in axis 1 gearbox Inspection Every 12 months Oil level in axis 2 gearbox Inspection Every 12 months Oil level in axis 3 gearbox Inspection Every 12 months Oil level in axis 4 gearbox Inspection Every 12 months Oil level in axis 5 gearbox Inspection Every 12 months Oil level in axis 6 gearbox Inspection Every 12 monthsi Robot ...

Page 118: ...yed when the battery needs to be replaced The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced See the replacement instruction for more details iv The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot powered off is less than 2 months The typical lifetime of a new battery ...

Page 119: ...movement press tending very severe palletizing applications major use of axis 1 movement and major use of bending backwards of axis 3 iv Depending on application the lifetime can vary The Service Information System SIS that is integrated in the robot software can be used as guidance when planning gearbox service for the individual robot This applies to gearboxes on axes 1 2 3 and 6 The lifetime of...

Page 120: ...ese procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level in axis 1 gearbox Use this procedure to inspect the oil level in the axis 1 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety infor...

Page 121: ... Gearbox oil Measure the oil level Required oil level max 5 mm below the oil plug hole Required oil level for tilted robots 15 20 mm below the oil plug hole 5 Where to find type of oil and total amount is detailed in Type of lub rication in gearboxes on page149 Adjust the oil level if required 6 Further information about how to fill with oil is found in section Changing oil axis 1 gearbox on page ...

Page 122: ...l plug vent hole A Oil plug filling and inspection B Oil plug draining C Location of gearbox on suspended mounted robot The following figure shows suspended mounted robot The gearbox axis 2 is located in the lower arm rotational center underneath the motor attachment xx0600002960 Continues on next page 122 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserve...

Page 123: ...g gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 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 This is a precaution to reduce the temperatu...

Page 124: ...e oil plug inspection hole 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 149 Adjust the oil level if required 6 Filling of oil is detailed further in the section Filling oil on page 155 Tightening torque 24 Nm Refit the oil plug 7 124 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance...

Page 125: ...ils See Type and amount of oil in gearboxes on page 149 Lubricating oil Content is defined in section Standard tools on page 346 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 6620 125 3HAC027151 001 Revision T C...

Page 126: ...ntering the robot working area 3 This is a precaution to reduce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 4 Shown in the figure Location of gear box on page 125 Open the oil plug inspection 5 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level max 5 mm below the inspec tion oil plug hole ...

Page 127: ...unt of oil in gearboxes on page 149 Lubricating oil Content is defined in section Stand ard tools on page 346 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 6620 127 3HAC027151 001 Revision T Copyright 2006 2018 ...

Page 128: ...obot working area 3 This is a precaution to reduce the tem perature dependency of the measure ment Make sure that the oil temperature is 25 C 10 C 4 Shown in the figure Location of gear box on page 127 Open the oil plug filling and inspection 5 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level 0 10 mm 6 Where to find type of oil and tota...

Page 129: ... references to these procedures in the step by step instructions below Inspecting the oil level in axis 5 gearbox Use this procedure to inspect the oil level in the axis 5 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety inform ation in the section Safety risks during work with gearbox lubricants oil or grease on page 37 1 Move...

Page 130: ...ction 6 xx0500002222 Measure the oil level Required oil level to the upper edge of the filling and inspection oil plug hole a 10 mm 7 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 149 Adjust the oil level if required 8 Further information about how to fill the oil may be found in the section Filling oil axis 5 on page 164 Tightening torque 24...

Page 131: ...required See references to these procedures in the step by step instructions below Inspecting the oil level in axis 6 gearbox Use this procedure to inspect the oil level in the axis 6 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety informa tion in the section Safety risks during work with gearbox lubricants oil or grease on pa...

Page 132: ... skipped Open the oil plug draining 7 Slowly turn axis 4 while adjusting axis 6 so that the oil plug draining always faces upwards Turn axis 4 until the axis 4 angle reads 45 to 55 8 A B C xx1400002786 A Oil plug hole B Required oil level C Gearbox oil 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 fo...

Page 133: ...il may be found in the section Tightening torque 24 Nm Refit the oil plugs 11 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 12 Product manual IRB 6620 133 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 6 Inspecting the oil level in axis 6 gearbox Continued ...

Page 134: ...cable harness xx0600002970 SMB BU box A Top cover connection box B Connection plate base C Connector R1 SMB D Connector R1 MP E Metal clamps F Cable harness G Cable guide cut away view H Continues on next page 134 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting cable harness ...

Page 135: ...ews metal clamp armhouse M6x16 quality 8 8 2 pcs G Required equipment Visual inspection no tools are needed Inspecting cable harness axes 1 6 Use this procedure to inspect cable harness of axes 1 6 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page Product manual IRB 6620 1...

Page 136: ...Check the cables 4 Shown in figure Location of cable har ness axes 1 6 on page 134 Check the metal clamps on the robot 5 Detailed in section Replace the cable harness if wear or damage is detected 6 Replacement of cable harness lower end axes 1 2 on page 185 Replacement of cable harness upper end on page 192 136 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights r...

Page 137: ...41 xx0600002980 Warning label concerning high temperature 4 pcs A Warning sign symbol of a flash located on motor cover 5 pcs B Warning label concerning brake release C Instruction label concerning lifting E Serial no from rating label G Continues on next page Product manual IRB 6620 137 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the inform...

Page 138: ... electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare part lists on page 351 Replace any missing or damaged labels 3 138 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reser...

Page 139: ...tended work range axis 1 is used Location of mechanical stop pin The axis 1 mechanical stop is located as shown in the figure xx0600002972 Mechanical stop pin axis 1 A Fixed mechanical stop B Required equipment Visual inspection no tools are required Continues on next page Product manual IRB 6620 139 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspecti...

Page 140: ...efore entering the robot working area 1 Inspect the axis 1 mechanical stop pin 2 If the mechanical stop pin is bent or damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop 140 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting the axis 1 mechanical stop pin C...

Page 141: ...3 Additional mechanical stops are not provided for axis 2 xx0600002938 Additional stop axis 1 A Attachment screws and washers 2 pcs B Fixed stop C Mechanical stop pin axis 1 D Continues on next page Product manual IRB 6620 141 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the additional mechanical stops ...

Page 142: ...204 003 Mechanical stop set axis 1 Includes Mechanical stop pin Attachment screw and washer Document for mechanical stop pin 3HAC025290 003 Mechanical stop set axis 3 Content is defined in section Standard tools on page 346 Standard toolkit Continues on next page 142 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the ad...

Page 143: ...al stops are damaged 2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 120 Nm Axes 2 and 3 115 Nm Article number is specified in Required equipment on page142 If any damage is detected the mechanical stops must be replaced Correct attachment screws Axis 1 M12 x 40 quality 12 9 Axis 3 M6 x 16 4 Product manual IRB 6620 143 3HAC027151 001 Revis...

Page 144: ...ed equipment A damper must be replaced if damaged Note Spare part art no Equipment 3HAC12320 1 Damper axes 2 3 3HAC024541 001 Damper axis 5 Content is defined in section Standard tools on page 346 3HAC15571 1 Standard toolkit Continues on next page 144 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the damper on axes 2 ...

Page 145: ...own in the figure Location of dampers on page 144 Check all dampers for damage and for cracks or existing impressions larger than 1 mm 2 Check attachment screws for deformation 3 Art no is specified in Required equipment on page 144 If any damage is detected the damper must be re placed with a new one 4 Product manual IRB 6620 145 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserv...

Page 146: ... replaced in case of detected damage 3HAC10830 1 Signal lamp Content is defined in section Stand ard tools on page 346 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 146 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 20...

Page 147: ...obot Before entering the robot working area 2 Art no is specified in Required equipment on page 146 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 3 Product manual IRB 6620 147 3HAC027151 001 Revision T Co...

Page 148: ...the pressure gauge 1 0 2 0 3 bar It should take at least 5 seconds for the pressure to reach 0 bar Close the cut off valve 2 The time is 5 seconds If the answer is YES Localize the leakage by following the procedures below If the answer is NO The system is OK Remove the leak testing equipment 3 Pressurize by opening the cut off valve 4 Spray suspected leak areas with leak detec tion spray Note Bub...

Page 149: ... myABB Business Portal www mypo rtal 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 lubrica...

Page 150: ...des pump with outlet pipe Oil dispenser Use the suggested dispenser or a similar one Orion OriCan article number 22590 pneumatic Nipple for quick connect fitting with o ring 150 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes Continued ...

Page 151: ...no Equipment etc Note Do not mix with other oils See Type and amount of oil in gear boxes on page 149 See Type and amount of oil in gearboxes on page 149 Lubricating oil Capacity 8 000 ml Oil collecting vessel Content is defined in section Special tools on page 347 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 346 Standard toolkit Continues on next pag...

Page 152: ...2 If the robot is suspended lift down the robot from its inverted position and secure it on the floor 3 Vessel capacity is specified in Re quired equipment on page 151 Collect drained oil in an oil vessel 4 Shown in figure Location of oil plugs on page 151 Remove oil plug filling in order to drain oil quicker 5 Note Draining is time consuming Elapsed time depends on the temperature of the oil Open...

Page 153: ...rease on page 37 2 Shown in figure Location of oil plugs on page 151 Open the oil plug filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 149 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspecting the oil level in axis 1 gearbox on page 120 4 Note Do not mix Kyodo Yushi TMO 150 with other oi...

Page 154: ...uipment Note Amount Art no Equipment etc Note Do not mix with other oil types See Type and amount of oil in gearboxes on page 149 See Type and amount of oil in gearboxes on page 149 Lubricating oil Capacity 5 000 ml Oil collecting vessel Content is defined in section Special tools on page 347 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 346 Standard t...

Page 155: ... with nipple and an oil collecting vessel CAUTION Drain as much oil as possible See Safety risks during work with gearbox lubricants oil or grease on page 37 3 Vessel capacity is specified in Required equipment on page 154 Note Draining is time consuming Elapsed time varies depending on the temperat ure of the oil Tightening torque 24 Nm Refit the oil plug 4 Filling oil Use this procedure to fill ...

Page 156: ...nspection 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 149 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspect ing the oil level in axis 2 gearbox on page 122 4 Note Don t mix Kyodo Yushi TMO 150 with other oil types 5 Tightening torque 24 Nm Refit the oil plug 6 156 Product manual IRB 6620 3H...

Page 157: ...oil types See Type and amount of oil in gear boxes on page 149 See Type and amount of oil in gearboxes on page 149 Lubricating oil Content is defined in section Special tools on page 347 3HAC021745 001 Oil exchange equipment Capacity 3 000 ml Oil collecting vessel Content is defined in section Standard tools on page 346 Standard toolkit Continues on next page Product manual IRB 6620 157 3HAC027151...

Page 158: ... Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 3 Remove the oil plug filling 4 Shown in the figure Location of gearbox on page 157 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel CAUTION Drain as much oil as possible See Safety risks during wo...

Page 159: ...safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 37 2 Shown in the figure Location of gearbox on page 157 Remove the oil plug filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 149 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspecting ...

Page 160: ... on page 347 3HAC021745 001 Oil exchange equipment Capacity 6 000 ml Oil collecting vessel Content is defined in section Standard tools on page 346 Standard toolkit 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 Required equipment on page 160 N...

Page 161: ...the upper arm back to its calibration posi tion horizontal position 6 Tightening torque 24 Nm Refit the oil plug draining 7 Filling oil The procedure below details how to fill 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 Required equipment on page 160 Note Action DANGER Turn off all electric pow...

Page 162: ...ting the oil level in axis 4 gearbox on page 127 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 149 Tightening torque 24 Nm Refit the oil plug filling 4 162 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 4 5 Changing oil axis 4 gearbox Continued ...

Page 163: ...hange equipment Capacity 4 000 ml Oil collecting vessel Content is defined in sec tion Standard tools on page 346 Standard toolkit Draining oil axis 5 The procedure below details how to change the oil in gearbox axis 5 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 163 Note Action This puts the oil p...

Page 164: ...l axis 5 The procedure below details how to change the oil in gearbox axis 5 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 163 Note Action Run axis 4 to a position where the oil plug filling is facing upwards 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read ...

Page 165: ...ing the oil level in axis 5 gearbox on page 129 4 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 149 Tightening torque 24 Nm Refit the oil plug filling 5 Product manual IRB 6620 165 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 4 6 Changing oil axis 5 gearbox Continued ...

Page 166: ... 347 3HAC021745 001 Oil exchange equip ment Vessel capacity Oil collecting vessel 500 ml Content is defined in section Standard tools on page 346 Standard toolkit Draining oil axis 6 The procedure below details how to drain oil from the gearbox axis 6 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 16...

Page 167: ... the kit is specified in Required equipment on page 166 Note Action 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 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety inform ation in the section Safety risks during work with gearbo...

Page 168: ...h other oil types 5 Tightening torque 24 Nm Refit the oil plug 6 Detailed in the section Inspecting the oil level in axis 6 gearbox on page 131 Inspect the oil level 168 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axis 6 gearbox Continued ...

Page 169: ...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 page36 Location of SMB battery The SMB battery SMB serial measurement board is lo...

Page 170: ...protection circuits Only re place with a specified spare part or an ABB approved equivalent For spare part no see Spare part lists on page 351 Battery pack Content is defined in section Standard tools on page 346 Standard toolkit See chapter Circuit diagram on page 353 Circuit diagram Removing battery Use this procedure to remove the SMB battery Note Action This is done in order to facilitate upda...

Page 171: ...of SMB battery on page 169 Remove the SMB battery Battery includes protection circuits Only replace with a specified spare part or with an ABB ap proved equivalent 7 Refitting battery Use this procedure to refit the SMB battery Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx0200000023 2 WAR...

Page 172: ...box and secure it with its attachment screws 4 Detailed in chapter Calibration section Updating revolution coun ters on page 313 Update the revolution counter 5 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 6 172 Product manual IRB 6620 3HAC027151 001 Revision T Copy...

Page 173: ...on page 120 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Oil spills discolors painted surfaces Oil spills on painted surfaces of the robot can result in discoloration Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil Special cleaning considerations...

Page 174: ...nd 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 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 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 m...

Page 175: ... sand dust and chips if it prevents cable movement Clean the cables if they have a crusty surface for example from dry release agents Product manual IRB 6620 175 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 3 Maintenance 3 5 1 Cleaning the IRB 6620 Continued ...

Page 176: ...This page is intentionally left blank ...

Page 177: ...perform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 339 Safety information 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 sur...

Page 178: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 179: ...o any stresses during the assembly work 3 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 Note Action Tension the bearing gradually until the...

Page 180: ...arted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 180 Product manual IRB 6...

Page 181: ...s of the correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page181 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and...

Page 182: ...nly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically c...

Page 183: ...52 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual IRB 6620 183 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights re...

Page 184: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 185: ...harness The procedure for replacing the upper end is detailed in the section Replacement of cable harness upper end on page 192 Location of cable harness axes 1 2 The cable harness for axes 1 2 is run throughout the base and frame as shown in the figure below xx0600002970 SMB BU unit A Continues on next page Product manual IRB 6620 185 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights r...

Page 186: ...rnal 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 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new ...

Page 187: ...he specified positions Axis 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 no significance 2 DANGER Turn off all electric power supply to the robot hydraulic pressure sup ply to the robot air pressure supply to the robot Before entering the robot work ing area 3 Shown in the figure Location of cable harness axes 1 2 on page 185 Remove the top cover connec tion box from the robot by re moving its ...

Page 188: ... in the figure Location of cable harness axes 1 2 on page 185 Disconnect all connectors at motors 1 R2 MP1 R2 FB1 and 2 R2 MP2 R2 FB2 7 Shown in the figure Location of cable harness axes 1 2 on page 185 Remove the metal clamps on the frame securing the cable harness 8 Continues on next page 188 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4...

Page 189: ...p through the cable guide in the center of the frame 11 Detailed in the section Replacement of cable harness upper end on page 192 Continue removal of the cable harness axes 3 6 12 Refitting The procedure below details how to refit the cable harness axes 1 2 Note Action Shown in the figure Location of cable harness axes 1 2 on page 185 Push the cable harness axes 1 2 carefully down through the cab...

Page 190: ...arness axes 1 2 on page 185 Reconnect all connectors at motors 1 R2 MP1 R2 FB1 and 2 R2 MP2 R2 FB2 5 Shown in the figure Location of cable harness axes 1 2 on page 185 Refit the metal clamps on the frame securing the cable har ness 6 Shown in the figure Location of cable harness axes 1 2 on page 185 Refit the top cover connection box 7 Continues on next page 190 Product manual IRB 6620 3HAC027151 ...

Page 191: ... General calibration information is included in section Calibration on page 305 DANGER Make sure all safety require ments are met when performing the first test run These are fur ther detailed in the section First test run may cause injury or damage on page 27 9 Product manual IRB 6620 191 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 1 Replacement of cable har...

Page 192: ...ness for the axes 3 to 6 runs throughout the lower and upper arm as shown in the figure below xx0600003078 Cable harness A Metal clamp at gearbox axis 3 B Attachment screws metal clamp at gearbox axis 3 M6x16 quality 8 8 2 pcs C Metal clamp lower arm 2 pcs D Attachment screws metal clamp lower arm M6x16 quality 8 8 2 2 pcs E Metal clamp armhouse F Attachment screws metal clamp armhouse M6x16 quali...

Page 193: ...on 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 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or crea...

Page 194: ...air pressure supply to the robot Before entering the robot working area 3 Detailed in the section Replacement of cable harness lower end axes 1 2 on page 185 Before starting the removal of cable harness axes 3 6 first remove cable harness axes 1 2 4 xx0600003024 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 place...

Page 195: ...crew M6X30 8 8 2 pcs C Cover motor axis 5 D Attachment screws motor xx0600003034 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 hold er The third screw M4x12 is located at the bottom of the cable holder securing the carrier 8 A Cable holder B Attachment screws M6x16 8 8 2 pcs C Atta...

Page 196: ...nnect all connectors at motor axes 3 R2 MP3 R2 FB3 and 4 R2 MP4 R2 FB 4 13 xx0600003083 A Metal clamp lower arm 2 pcs B Metal clamp gearbox axis 3 C Metal clamp armhouse Remove the metal clamps two on the lower arm one on gearbox axis 3 and one on the armhouse 14 xx1400002582 Foundry Plus Remove the Foundry Plus arm house cover 15 Use caution and pull out the cable harness of the upper arm 16 Tie ...

Page 197: ... at motor axes 3 R2 MP3 R2 FB3 and 4 R2 MP4 R2 FB4 4 xx1500002404 Refit covers motor axes 3 and 4 Make sure to turn the revolution indicator with the green side towards axis 4 center 5 xx0600003034 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 hold er The third screw M4x10 is located at the bottom ...

Page 198: ... screws M6x30 8 8 2 pcs C Cover motor axis 5 D Attachment screws xx0600003030 Refit the metal clamp securing the cable harness at axis 5 11 A Cable harness B Motor axis 5 C Attachment screws M6x16 8 8 2 pcs D Metal clamp Continues on next page 198 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of cable harness upper end Cont...

Page 199: ... xx0600003024 Standard Fit the wrist cover 13 A Cover wrist unit xx1400002579 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 14 Continues on next page Product manual IRB 6620 199 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of cable harness upper end Cont...

Page 200: ... Foundry Plus Make sure the gasket on the adapter ring is undamaged Replace if damaged 17 xx1400002582 Foundry Plus Fit the Foundry Plus cover on the adapter ring 18 Make sure the gasket on the adapter ring is undamaged Replace if damaged 19 Continues on next page 200 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of cable h...

Page 201: ...age 319 General calibration information is included in section Calibration on page 305 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 page27 21 Product manual IRB 6620 201 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of cabl...

Page 202: ...nd in Spare part lists on page 351 xx0600003035 Upper arm A Lower arm B Motor axis 1 C Frame D Base E Gearbox axis 1 F Attachment screws base M12x80 quality 12 9 Gleitmo 16 pcs G Required equipment Note Art no Equipment etc Instruction 3HAC026600 002 is en closed 3HAC026597 001 Lifting accessory robot Continues on next page 202 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ...

Page 203: ...rence 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 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for t...

Page 204: ...elease the brakes if necessary as detailed in section Manually releasing the brakes on page 79 xx0600003125 Run the robot to the position shown in the figure to the right 2 Run the overhead crane to a position above the robot 3 Continues on next page 204 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of complete arm system C...

Page 205: ...rn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot work ing area 5 Detailed in section Changing oil axis 1 gearbox on page 151 Drain the oil from gearbox axis 1 6 Disconnect the cabling in the rear of the robot base and re move the cable support plate in side the base 7 How to replace the cabling is detail...

Page 206: ...ing the brakes is detailed in section Manually releasing the brakes on page 79 xx0600003100 The hoisting block is used to balance the upper arm See the lifting instructions Note The brake on axis 3 shall be re leased during the lift until the roundsling between the wrist and the frame tranfers the load of the frame See figure to the right A Lifting tool B Roundsling C Lifting chain D Hoisting bloc...

Page 207: ... wear against sharp edges 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 unbal anced despite earlier adjust ments The risk of damaging the interfaces is bigger if the load is lowered unbalanced 15 Refitting arm system The procedure describes how to lift and refit...

Page 208: ...ons before lift ing Used to adjust the balance of the arm sys tem in order to lift it completely level Note There is an alternate method of lifting the complete armsystem described below Releasing the brakes are detailed in sec tion Manually releasing the brakes on page 79 xx0600003101 A Lifting tool B Roundsling C Lifting chain D Hoisting block Continues on next page 208 Product manual IRB 6620 3...

Page 209: ...the lifting instructions Note The brake on axis 3 shall be released during the lift until the roundsling between the wrist and the frame transfers the load of the frame See figure to the right A Lifting tool B Roundsling C Lifting chain D Hoisting block E Roundsling used to transfer the load of the frame CAUTION The complete arm system weighs 590 kg All lifting equipment used must be sized ac cord...

Page 210: ...o the right If using guide pins of different lengths fit the pin with maximal length of 130 mm on the right side of the gearbox seen from be hind Note Lubricate the guide pins for easier fitting of the arm system 7 Lubricate the outer surface of the gearbox for easier mating of the gearbox and arm system 8 Continues on next page 210 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 ...

Page 211: ...es in frame for guide pins shown from above Shown in the figure Location of arm sys tem on page 202 Remove the guide pins and secure the arm system to the base with its 16 attachment screws and washers 10 M12 x 80 12 9 quality gleitmo Tightening torque 105 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 342 before fitting Refit the axis 1 moto...

Page 212: ... page319 General calibration information is included in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 16 212 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of co...

Page 213: ...hen replacing the turning disk 3HAB3772 65 1pc 21520431 20 6 pcs O ring Wrist type 1 For IRB 6620 Foundry Plus 3HAB3772 64 1 pc O ring Wrist type 2 Must be replaced when replacing the turning disk 3HAB3772 61 12 pcs Used to lubricate the o rings 3HAB3537 1 Grease Loctite 574 3HAC034903 001 Flange sealant Content is defined in section Standard tools on page 346 Standard toolkit These procedures inc...

Page 214: ...orking area 2 Remove any equipment fitted to the turning disk 3 See section Changing oil axis 6 gear box on page 166 Drain the axis 6 gearbox 4 Shown in the figure Location of turning disk on page 213 Remove the attachment screws that secure the turning disk 5 Remove the turning disk 6 Foundry Plus 7 Remove old flange sealant residues and other con tamination from the contact surfaces Continues on...

Page 215: ...ure the turning disk with its attachment screws 3 Tightening torque 175 Nm Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page342 before fit ting Detailed in the section Performing a leak down test on page 178 Perform a leak down test of the gearbox axis 6 4 See section Changing oil axis 6 gearbox on page 166 Refill the axis 6 gearbox with oil 5 Ref...

Page 216: ...orming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 7 216 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Continued ...

Page 217: ...rist unit attachment screws G Cable harness axis 6 H Cable harness axis 5 I Required equipment Note Art no Spare part no Equipment etc See Spare part lists on page 351 Wrist unit See Spare part lists on page 351 Wrist unit insulated See Spare part lists on page 351 Retrofit set Foundry Plus wrist Continues on next page Product manual IRB 6620 217 3HAC027151 001 Revision T Copyright 2006 2018 ABB A...

Page 218: ...dant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference c...

Page 219: ...on page 192 Remove the cable harness axes 5 and 6 6 CAUTION The complete wrist unit weighs 96 kg All lifting equipment used must be sized accordingly 7 Secure the wrist unit with a roundsling in an over head crane 8 Shown in the figure Location of wrist unit on page 217 Unscrew the eight attachment screws securing the wrist unit 9 Note Do not damage the cylindric al pin in the process Remove the w...

Page 220: ...2579 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 8 xx1400002580 Foundry Plus Make sure the washers are fitted in the gasket holes Refit the wrist cover Foundry Plus 9 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the cal ibration tools Recalibrate the robot 10 ...

Page 221: ...requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 27 12 Product manual IRB 6620 221 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 2 Replacement of wrist unit Continued ...

Page 222: ... arm E Upper arm F Required equipment Note Art no Spare part no Equipment etc See Spare part lists on page 351 Upper arm Axes 3 4 Replace only if damaged O ring Instruction 3HAC026600 002 is enclosed 3HAC026597 001 Lifting tool Lifting chain Roundsling Always use in pairs Guiding pins Hoisting block Used to lubricate o rings 3HAB3537 1 Grease Continues on next page 222 Product manual IRB 6620 3HAC...

Page 223: ...If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 320 I...

Page 224: ...procedure carefully CAUTION The complete upper arm incl gearbox axis 3 weighs 282 kg without any additional equipment fitted Use a suitable lifting device to avoid injury to personnel 5 Art no is specified in Required equipment on page 222 xx0600003102 Fit the lifting tool on the upper arm as de tailed in the enclosed instructions Also fit a hoisting block to the front which is used to adjust the ...

Page 225: ... four screws inside the hole in the lower arm 10 Remove the complete upper arm and put it on the floor Let the upper arm lean on its side 11 Refitting The procedure below details how to refit the upper arm Note Action Make sure the o ring is fitted to the gearbox 1 Lightly lubricate the o ring with grease CAUTION The complete upper arm incl gearbox axis 3 weighs 282 kg without any additional equip...

Page 226: ...rbox Note Do not forget the four screws inside the hole in the upper arm 5 Remove the guiding pins 6 Detailed in the section Replacement of motor axis 3 on page 253 Refit motor axis 3 7 xx0600003083 Refit the metal clamps securing the cable harness on the lower arm and armhouse 8 A Metal clamp lower arm 2 pcs B Metal clamp gearbox axis 3 C Metal clamp armhouse Detailed in section Performing a leak...

Page 227: ...ed in Calibrating with Axis Calibration method on page319 General calibration information is included in section Calibration on page 305 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 page27 13 Product manual IRB 6620 227 3HAC027151 001 Revision T Copyright 2006 2018 ABB All ...

Page 228: ...r arm C Hole in lower arm D Attachment screws M16x50 quality 12 9 Gleitmo 16 pcs E xx0600003059 Lower arm A Hole in lower arm B Gearbox axis 2 C Attachment screws M16x50 quality 12 9 Gleitmo 16 pcs D Continues on next page 228 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 4 Replacement of lower arm ...

Page 229: ...e robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repai...

Page 230: ... to the robot Before entering the robot working area 3 Detailed in the section Replacement of cable harness upper end on page 192 Remove the cable harness axes 3 6 4 Let the cable harness hang loose without it getting dam aged in the proceeded removal procedure 5 Detailed in the section Replacement of the upper arm on page 222 Remove the upper arm 6 Secure the lower arm with a roundsling in an ove...

Page 231: ...e attachment screws and washers secur ing the lower arm to gearbox axis 2 6 M16x50 quality 12 9 gleitmo 16 pcs Tightening torque 300 Nm Remove the guiding pins 7 Secure the upper arm with a roundsling and lift it to its mounting position 8 Detailed in the section Replacement of the upper arm on page 222 Refit the upper arm 9 Detailed in the section Replacement of cable harness upper end on page 19...

Page 232: ...orming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 12 232 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 4 4 Replacement of lower arm Continued ...

Page 233: ...D2 xx0600003052 Attachment screws 4 pcs A SMB BU unit B Velcro strap C Battery pack 2 pole battery contact D1 Battery pack 3 pole battery contact D2 SMB BU box E Serial measurement unit SMB DSQC 633A F Serial measurement unit SMB RMU 101 F Brake release unit BU DSQC 1050 G Push button guard H Cover push button guard I Gasket Foundry Plus J Continues on next page Product manual IRB 6620 233 3HAC027...

Page 234: ...obot to the calibration position 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 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 32 3 Shown in the figure Location of SM...

Page 235: ... the lock while pulling the connector upwards 6 xx0600003053 Unscrew the hexagon nuts securing the SMB unit just enough to pull the SMB unit out 7 A Hexagon nut M5 B Tooth lock washer 6 4 fzb C Hexagon screw M5x12 quality 8 8 Pull the SMB unit out carefully 8 Continues on next page Product manual IRB 6620 235 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 5 1 Repl...

Page 236: ...B7 to the SMB cover and tighten with 6 Nm 2 Connector R1 G Reconnect the battery cable 3 Make sure the lock on the battery cable connect or R1 G snaps into place during refitting Shown in the figure Location of SMB unit on page 233 Put the SMB BU unit back into its box and refit the attachment screws 4 Detailed in section Updating revolution counters on page 313 Update the revolution counters 5 Co...

Page 237: ...forming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 6 Product manual IRB 6620 237 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 5 1 Replacement of SMB unit Continued ...

Page 238: ...ke release unit BU DSQC1050 G Push button guard H Cover push button guard I Gasket Foundry Plus J Required equipment Note Article number Equipment etc DSQC1050 3HAC066539 001 Brake release board including harness and bracket Content is defined in section Standard tools on page 346 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required ...

Page 239: ...fitting of the brake release board Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board 5 Unscrew the attachment screws of the SMB BU unit and carefully lift the unit out of its box 6 Let the battery stay connected to avoid the need of synchronization of the robot CAUTION Clean cover from metal residues before opening Metal residues can cause sho...

Page 240: ...en the SMB cover is refitted 3 Shown in the figure Location of brake release board on page 238 Art no is specified in Required equip ment on page 238 Put the SMB BU unit carefully back into its box and refit its attachment screws 4 Verify that the robot cabling is positioned cor rectly according to previously taken pic ture notes WARNING Screened cables must not get in contact with the brake relea...

Page 241: ...e 313 If the battery has been disconnected the revolu tion counter must be updated 10 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 11 Product manual IRB 6620 241 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the brake...

Page 242: ...Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant Location of motor The motor axis 1 is located as shown in the figure below xx0600003037 Motor axis 1 A Motor attachment screws and washers B Cable gland C Cover D Continues on next page 242 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights re...

Page 243: ...oolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum toolkit Required if Calibration Pendulum is the valid cal ibration method for the robot Delivered as a set of calib ration tools 3HAC055412 001 Calibration tool box Axis Calibration Required if Axis Calibra tion is the valid calibration method for the robot These procedures include references to the tools re ...

Page 244: ...reference calibration for Axis Calibration in Reference calibration routine on page 320 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable pa...

Page 245: ...dingly 9 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage 10 Remove the motor by gently lifting it straight up 11 Refitting motor axis 1 The procedure below details how to refit motor axis 1 Note Action 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 ...

Page 246: ...l connectors beneath the motor cover 10 Make sure the cover is tightly sealed Refit the cable gland cover at the cable exit with its two attachment screws 11 Make sure the cover is tightly sealed Refit the motor cover with its four attachment screws 12 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calib ration tools Recalibrate the robot 13 Axis Calib...

Page 247: ...e 351 Motor including pin ion Must be replaced when re assembling motor 21522012 430 O ring For lubricating the o ring 3HAB3537 1 Grease Always use the removal tools in pairs 3HAC14973 1 Removal tool motor M12x For guiding the motor Guides are to be used in pairs 3HAC15521 2 Guide pins M10 x 150 3HAC026061 001 Lifting tool motor ax 2 3 3HAC12342 1 Extension bar 300 mm for bits 1 2 Continues on nex...

Page 248: ...to the tools re quired Other tools and pro cedures may be re quired See refer ences to these pro cedures in the step by step instructions below See chapter Circuit diagram on page 353 Circuit diagram 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 repa...

Page 249: ...low details how to remove the motor axis 2 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair proced ure 1 Releasing brakes are detailed in section Manually releasing the brakes on page 79 Secure the robot from collapsing once the motor axis 2 is removed by following the procedure detailed below Move the lower arm as far back as possible ...

Page 250: ... motor attachment holes 11 Shown in the figure Location of motor on page247 Art no is specified in Required equipment on page 247 If required press the motor out of position by fitting the removal tool motor to the remaining motor attach ment holes 12 Shown in the figure Location of motor on page247 Always use the removal tools in pairs Art no is specified in Required equipment on page 247 Remove ...

Page 251: ...it the lifting tool motor axis 2 3 4 to the motor 4 Art no is specified in Required equip ment on page 247 Fit the two guide pins in the two lower motor attachment holes 5 Shown in the figure Location of motor on page 247 CAUTION The motor weighs 38 kg All lifting equipment used must be sized accordingly 6 Lift the motor and guide it onto the guide pins as close to the correct position as possible...

Page 252: ...e figure Location of motor on page 247 Refit the cable gland cover at the cable exit with its two attachment screws 14 Make sure the cover is tightly sealed Refit the cover on top of the motor with its four attachment screws 15 Detailed in Performing a leak down test on page 178 Perform a leak down test 16 Detailed in the section Changing oil axis 2 gearbox on page 154 Refill the gearbox with oil ...

Page 253: ... axis 3 Must be replaced when reas sembling motor 21522012 430 O ring For lubricating the o ring 3HAB3537 1 Grease 3HAB3409 86 Bolts M16x60 for mechanical stop axis 3 For guiding the motor 3HAC15521 1 Guide pins M10 x 100 For guiding the motor 3HAC15521 2 Guide pins M10 x 150 Used to rotate the motor pin ion when mating it to the gear when brakes are released with 24 VDC power supply 3HAC17105 1 R...

Page 254: ...alibrating 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 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previo...

Page 255: ... on page 79 Secure the robot from collapsing once the motor axis 3 is removed by following the procedure detailed below Move the lower arm as far back as possible Release the brakes on motor axis 2 and let the lower arm rest on its mechanical stop Also release the brakes on motor axis 3 and let the up per arm rest on its mechanic al stop The lower and upper arms now rests on their respective mecha...

Page 256: ...ed in Required equipment on page 253 Fit the two guide pins in two of the motor attachment screw holes 11 Art no is specified in Required equipment on page 253 Press the motor out of position by fitting removal tool motor to the re maining motor attachment screw holes 12 Always use the removal tools in pairs Art no is specified in Required equipment on page 253 Apply the lifting tool motor axis 2 ...

Page 257: ...cified in Required equipment on page 253 Fit the two guide pins in the two lower motor at tachment holes 4 Shown in the figure Location of mo tor on page 253 CAUTION The motor weighs 25 kg All lifting equipment used must be sized accordingly 5 Lift the motor and guide it onto the guide pins as close to the correct position as possible without pushing the motor pinion into the gear 6 Remove the lif...

Page 258: ...sure the cover is tightly sealed Refit the cable gland cover at the cable exit with its two attachment screws 14 Shown in the figure Location of mo tor on page 253 Make sure the cover is tightly sealed Refit the cover on top of the motor with its four attachment screws 15 Remove the equipment used to unload the upper arm 16 Detailed in the section Performing a leak down test on page 178 Perform a ...

Page 259: ...rming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 20 Product manual IRB 6620 259 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 3 Replacement of motor axis 3 Continued ...

Page 260: ...2 430 O ring Used to lubricate the o ring 3HAB3537 1 Grease Option Foundry Plus 12340011 116 Loctite 574 Flange sealant For guiding the motor 3HAC15520 1 Guide pins M8 x 100 For guiding the motor 3HAC15520 2 Guide pins M8 x 150 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply 3HAC17105 1 Rotation tool 24 VDC max 1 5 A Power supply For rel...

Page 261: ...ools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new...

Page 262: ...5 In order to release the brake connect the 24 VDC power supply 7 Shown in the figure Location of motor on page 260 Unscrew the motors four attachment screws and plain washers 8 Fit the two guide pins in two of the motor attachment screw holes 9 Art no is specified in Required equipment on page 260 If required press the motor out of position by fitting removal tool motor to the motor attachment sc...

Page 263: ...the motor pinion does not get damaged Make sure the motor is turned the right direction that is the cables facing for wards xx0200000165 The rotation tool is used beneath the mo tor cover directly on the motor shaft as shown in figure above A Rotation tool Remove the guide pins 7 4 pcs M8 x 25 tightening torque 24 Nm Secure the motor with four attachment screws and plain washers 8 Disconnect the b...

Page 264: ...d on page 319 General calibration information is included in section Calibration on page 305 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 page27 16 264 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 6 4 Replacement o...

Page 265: ...Art no Equipment etc For spare part number see Spare part lists on page 351 Motor For spare part number see Spare part lists on page 351 Retrofit set Foundry Plus wrist For spare part number see Spare part lists on page 351 Retrofit set Foundry Plus upper arm axis 4 Must be replaced when reassembling motor 21522012 430 O ring For lubricating the o ring 3HAB3537 1 Grease Option Foundry Plus 1234001...

Page 266: ...ools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are ...

Page 267: ...n in the figure in section Loca tion of motor on page 265 Remove the cable gland cover at the cable exit by unscrewing its two attachment screws 6 Remove the cover on top of the motor by unscrew ing its four attachment screws 7 Disconnect all connectors beneath the motor cover and remove the cable of the axis 5 motor 8 Shown in the figure in the section Location of motor on page 265 Pull the cable...

Page 268: ...ctor R2 MP5 in the motor pin 2 pin 5 Art no is specified in Required equip ment on page 265 Fit the two guide pins in two of the motor attach ment holes 4 Make sure the motor pinion does not get damaged Fit the motor with guidance from the pins making sure the motor pinion is properly mated to the gear of axis 5 5 4 pcs M8 x 25 tightening torque 24 Nm Secure the motor with four attachment screws a...

Page 269: ...g manual Calibration Pendu lum enclosed with the calibration tools Re calibrate the robot 17 Axis Calibration is described in Calib rating with Axis Calibration method on page 319 General calibration information is in cluded in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run...

Page 270: ...Motor including pinion Motor including pinion Foundry Plus Includes motor pinion o ring 21522012 430 See spare part number in Spare part lists on page 351 Motor including pinion insulated Must be replaced when reas sembling motor 21522012 430 O ring Must be replaced when repla cing motor 3HAC048560 001 Gasket Must be replaced when opening cover 3HAC033489 001 Gasket cover Continues on next page 27...

Page 271: ...Axis Calibration is the valid calibration meth od for the robot These procedures include references to the tools re quired Other tools and proced ures may be required See references to these procedures in the step by step instructions be low See chapter Circuit diagram on page 353 Circuit diagram Deciding calibration routine Decide which calibration routine to be used based on the information in t...

Page 272: ...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 275 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 Move the robot to ...

Page 273: ... Refitting motor The procedure below details how to refit 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 275 Note Action Art no is specified in Required equipment on page 270 Make sure the o ring on the cir...

Page 274: ... washers 6 Disconnect the brake release voltage 7 Reconnect all connectors beneath the motor cover 8 Make sure the cover is tightly sealed Refit the cover on top of the motor with its five attachment screws 9 Pendulum Calibration is described in Operating manual Calibration Pen dulum enclosed with the calibration tools Re calibrate the robot 10 Axis Calibration is described in Calib rating with Ax...

Page 275: ...g additions Note Action 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 1 xx1500002524 Remove the rear motor cover by unscrewing the five attachment screws 2 A Motor unit B Connection box C Attachment screw 5 pcs D Rear motor cover E Gasket Continue to remove the motor unit accordi...

Page 276: ...house F Washer G Rear motor cover H Sealing J Loctite 574 Apply Mercasol 3106 on the motor end cover 6 xx1400000992 Apply Loctite 574 flange sealant on the contact surface 7 Apply grease on the o ring on the motor 8 Continue to refit the new motor according to section Refitting motor on page 273 9 276 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 R...

Page 277: ...ase D Frame E Protection pipe axis 1 F O ring G Required equipment Note Art no Spare part no Equipment etc Includes gearbox o ring See Spare part lists on page 351 Gearbox axis 1 Replace only when dam aged 3HAB3772 93 O ring 380 6x3 53 23x3 6 3HAB3772 97 O ring 3 pcs Continues on next page Product manual IRB 6620 277 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 ...

Page 278: ...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 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference va...

Page 279: ...used must be sized accordingly 6 Lift the robot without the base and put it safely on its side on the floor 7 Detailed in section Orienting and securing the robot on page 87 Remove the robot s attachments screws in order to unfasten the base from the founda tion 8 Art no is specified in Required equipment on page 277 Fit two lifting eyes on each side of the gearbox and secure it with a roundsling ...

Page 280: ... All lifting equipment used must be sized accordingly 15 Remove the gearbox 16 Refitting The procedure below details how to remove the gearbox axis 1 Note Action Mounting of the support base and gear axis 1 is detailed in section Removal on page 279 If the base not already is resting on the support base and gear axis 1 this should be done first 1 Continues on next page 280 Product manual IRB 6620 ...

Page 281: ...er of gearbox 1 with its attachment screws 4 Art no is specified in Required equip ment on page 277 Fit two lifting eyes on each side of the gear box and secure it with a roundsling 5 Fit two guide pins in two of the attachment holes parallel to each other 6 CAUTION The gearbox weighs 108 kg All lifting equipment used must be sized accordingly 7 Lift the gearbox on to the guide pins and lower it c...

Page 282: ...rbox unit 108 kg All lifting equipment used must be sized accordingly 10 Lift the robot base and gearbox 1 to allow removing the support base and gear 11 Detailed in section Orienting and securing the robot on page 87 Secure the base to the mounting site 12 CAUTION The complete arm system weighs 590 kg All lifting equipment used must be sized ac cordingly 13 Continues on next page 282 Product manu...

Page 283: ...lternate method of lifting the complete armsystem described below 14 Make sure the lift is done completely level How to adjust the lift is described in the enclosed instruction to the lifting tool Read the instructions before lifting xx0600003101 A Lifting tool B Roundsling C Lifting sling D Hoisting block Continues on next page Product manual IRB 6620 283 3HAC027151 001 Revision T Copyright 2006 ...

Page 284: ...ling between the wrist and the frame transfers the load of the frame Releasing the brakes is detailed in sec tion Manually releasing the brakes on page 79 xx0600003100 A Lifting tool B Roundsling C Lifting chain D Hoisting block E Roundsling used to transfer the load of the frame Shown in the figure Location of gearbox axis 1 on page 277 Refit the robot to the base with its attach ment screws and ...

Page 285: ...Pendulum enclosed with the calibration tools Recalibrate the robot 20 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 319 General calibration information is in cluded in section Calibration on page305 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 dam...

Page 286: ...HAB3772 91 O ring 339 3x5 7 For lubricating o rings 3HAB3537 1 Grease Instruction 3HAC026600 002 is enclosed 3HAC026597 001 Lifting tool For lifting gearbox 3HAC025214 001 Lifting tool Roundsling Always use in pairs 3HAC13056 4 Guide pins M12x250 Always use in pairs 3HAC13056 3 Guide pins M12x200 Used to turn the gear in correct position 3HAC020999 001 Crank Content is defined in section Standard ...

Page 287: ... refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 320 If no previous reference values exist ...

Page 288: ...d equipment on page 286 xx0600003099 Fit the lifting tool on the upper arm and secure the robot in an overhead crane 4 A Lifting tool B Roundsling C Lifting chain D Hoisting block Detailed in the section Changing oil axis 2 gearbox on page 154 Drain the oil from gearbox axis 2 5 Continues on next page 288 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved...

Page 289: ...earbox axis 2 on page 286 Remove the attachment screws M16x50 16 pcs that secure the lower arm to gearbox axis 2 9 Remove the upper and lower arms and put them down on the floor 10 Detailed in the section Replacement of motor axis 2 on page 247 Remove motor axis 2 11 Remove two attachment screws M12x60 parallel to each other 12 Fit two guide pins in the holes parallel to each other 13 CAUTION The ...

Page 290: ...ring the gearbox to the frame 16 Remove the gearbox and put it in a place where it will not cannot be damaged 17 Wipe away residual oil and paint 18 Refitting The procedure below details how to refit gearbox axis 2 Note Action xx0600003128 Make sure the o ring is fitted to the gearbox Lightly lubricate it with grease 1 A O ring 3HAB3772 91 Continues on next page 290 Product manual IRB 6620 3HAC027...

Page 291: ...ins in two of the attachment holes parallel to each other 4 Lift the gearbox on to the guide pins and push it in mounting position 5 M12x60 24 pcs Refit the gearbox with its attach ment screws 6 Tightening torque 120 Nm CAUTION The upper and lower arms in cl gearboxes axes 2 and 3 weighs 455 kg All lifting equipment used must be sized accordingly 7 Continues on next page Product manual IRB 6620 29...

Page 292: ...page 247 Refit motor axis 2 11 Detailed in the section Replacement of cable harness lower end axes 1 2 on page 185 Refit the cable harness axes 1 3 12 Detailed in the section Changing oil axis 2 gearbox on page 154 Fill the gearbox axis 2 with oil 13 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 14 Axis Calibrat...

Page 293: ...rm ing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 15 Product manual IRB 6620 293 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 7 2 Replacement gearbox axis 2 Continued ...

Page 294: ... part no Equipment etc Includes gearbox o ring See Spare part lists on page 351 Gearbox axis 3 Replace only if damaged 3HAB3772 92 O ring Used to lubricate the o ring 3HAB3537 1 Grease Instructions 3HAC 026600 002 is enclosed 3HAC026597 001 Lifting tool For lifting gearbox 3HAC025214 001 Lifting tool Content is defined in section Standard tools on page 346 Standard toolkit Continues on next page 2...

Page 295: ...refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 320 If no previous reference values exist a...

Page 296: ...pecified in Required equipment on page 294 While the upper arm is resting on its side on the floor fit the lifting tool in the uppermost hole of the gearbox 6 CAUTION The gearbox weighs 51 kg All lifting equipment used must be sized accordingly 7 Secure the gearbox with a roundsling in an overhead crane 8 Shown in the figure Location of gear box axis 3 on page 294 Remove the attachment screws secu...

Page 297: ...its mounting position 5 Refit the gearbox while the upper arm is resting on its side on the floor 6 Detailed in the section Replacement of the upper arm on page 222 Refit the upper arm 7 Detailed in the section Changing oil axis 3 gearbox on page 157 Fill the gearbox axis 3 with oil 8 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Re...

Page 298: ...ming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 10 298 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 7 3 Replacement of gearbox axis 3 Continued ...

Page 299: ...nt screws gearbox B Oil plug draining C Oil plug filling D Turning disk E Attachment screws turning disk F xx0200000219 Gearbox axis 6 IRB 6620 Foundry Plus A Attachment screws and washers B Oil plug draining C Oil plug filling D Continues on next page Product manual IRB 6620 299 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 4 Repair 4 7 4 Replacement of gearbox axis 6 ...

Page 300: ...ant Content is defined in sec tion Standard tools on page 346 Standard toolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum toolkit Required if Calibration Pendulum is the valid calib ration method for the robot Delivered as a set of calib ration tools 3HAC055412 001 Calibration tool box Axis Calibration Required if Axis Calibration is the valid calibration me...

Page 301: ...ine on page 320 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removal gearbox The procedure ...

Page 302: ...age the motor pinion Remove the gearbox axis 6 by lifting it out carefully 7 Refitting gearbox The procedure below details how to refit gearbox axis 6 Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the ro bot air pressure supply to the robot Before entering the robot working area 1 Continues on next page 302 Product manual IRB 6620 3HAC027151 001 Re...

Page 303: ... the figure Location of gearbox on page 299 Make sure the gears of the gearbox mate with the gears of the motor Shown in the figure Location of gearbox on page 299 Secure the gearbox with the attachment screws and washers 6 8 pcs or 18 pcs depending on wrist ver sion M8 x 40 12 9 quality Gleitmo Tight ening torque 30 Nm Reused screws may be used providing they are lubricated as detailed in section...

Page 304: ...brate the robot 10 Axis Calibration is described in Calibrating with Axis Calibration method on page 319 General calibration information is included in section Calibration on page 305 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 11 304 Product manual IRB 6620 3HAC02...

Page 305: ...at is used for calibration of the robot Calibration position A generic term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine ca...

Page 306: ... in the Cartesian coordinate system for the robot Absolute accuracy calibration option al 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 ...

Page 307: ...ugh the calibration procedure step by step Levelmeter calibration alternative method Levelmeter calibration is referred to as the alternative method for calibration of ABB robots because of the less accurate values obtained during calibration The method uses the same principles as Calibration Pendulum but does not have as good of mechanical tolerances to the toolkit parts as the standard method wi...

Page 308: ...or the calibration tools are listed in the section Special tools on page 347 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit including the Operating manual Calibration Pendulum which describes the method and the different routines further 308 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 1 2 Calib...

Page 309: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 313 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 co...

Page 310: ...chronization position for each axis Synchronization marks IRB 6620 The illustration below shows the positions of the synchronization marks on all axes of the robot xx0600003096 Synchronization mark axis 1 A Continues on next page 310 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position f...

Page 311: ...ization mark axis 4 D Synchronization mark axis 5 E Synchronization mark axis 6 F Product manual IRB 6620 311 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 312: ...nes 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 312 Product manual IRB 6620 3HAC027151 001 Rev...

Page 313: ...cator is located as shown in figure xx1500002405 Function Before doing an update of the revolution counter the revolution indicator must be checked The green side of the indicator shall point towards axis centre The indicatior shows if axis 4 is turned correctly or has been rotated more than 360 If the indicator has been turned the robot has to be jogged manually in the Continues on next page Prod...

Page 314: ... indicator before synchonization Note Action xx1500002404 Make sure that the green side of the indicator is turned towards the axis 4 center 1 xx1500002449 If not Jog the robot manually in the opposite direction to reach the correct position 2 Continues on next page 314 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 3 Updating revoluti...

Page 315: ...ed update the revolution counter 3 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...

Page 316: ...date the revolution counter and check the synchronization marks again try both directions if needed Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant IRC5 Action On the ABB menu tap Calibration xx1500000942 1 Continues on next page 316 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rig...

Page 317: ...RobotWare 6 02 and later 3 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 Continues on next page Product manual IRB 6620 317 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 318: ...s displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn ma...

Page 319: ...vable 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 inse...

Page 320: ...lues When reference calibration is performed the robot is restored to the status given by the reference values Note 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 Update revolution counters Choose this routine to make a rough calibration of each manipul...

Page 321: ... its working position not standing on a floor To calibrate a suspended robot with the fine calibration routine the robot must first be taken down and then be mounted standing on the floor Product manual IRB 6620 321 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 1 Description of Axis Calibration Continued ...

Page 322: ...gs may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection ...

Page 323: ...solution Note 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 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 calibra tion tool size 1 There is a cavi...

Page 324: ...d calibration pins and or bushings The figure does not show installed calibration tools A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows xx1600000001 xx1600000011 Continues on next page 324 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibra...

Page 325: ... in the bushing Replace damaged parts with new if needed Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC056806 001 Protection cover and plug set Product manual IRB 6620 325 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 326: ...re on the FlexPendant 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 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 ...

Page 327: ...ant while conducting it Note Action 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 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use...

Page 328: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 326 Follow the instructions given on the FlexPendant 4 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 Action Situation Press and...

Page 329: ...alibration 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 Note Action SafeMove generates the message Safety control ler not sync...

Page 330: ... Unsynchronized time limit expired SafeMove message anytime during Axis Calibration routine Note Action SafeMove generates the message Unsynchron ized time limit expired anytime xx1500002482 1 Press OK to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page 330 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB Al...

Page 331: ...ection cover and plug set 3HAC056806 001 xx1500000952 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 3 Protection cover and plug set 3HAC056806 001 Product manual IRB 6620 331 3HAC027151 001 Revision T Copyright 2006 20...

Page 332: ...ndulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools 332 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 333: ...change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 310 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm Remove any calibration equipment fr...

Page 334: ... page 310 and Updating revolution counters on page 313 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

Page 335: ...s Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance ...

Page 336: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 336 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 337: ...attery 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 Product manual IRB 6620 337 3HAC027151 001 Revision T Copyright 2006 2018 ABB All r...

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Page 339: ... ISO 9283 1998 Classification of air cleanliness EN ISO 14644 1 2015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements ...

Page 340: ...y requirements for industrial robots and robot systems ANSI RIA R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 340 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 7 Reference information 7 1 Applicable standards Continued ...

Page 341: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume Product manual IRB 6620 341 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 7 Reference information 7 2 Unit conversion ...

Page 342: ...uld 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...

Page 343: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 344: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 344 Product manual IRB 6620 3HAC027151 001 Rev...

Page 345: ...sory 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 Note Action CAUTION The robot weighs 900 kg All lifting accessories used must be sized accord ingly Product manual IRB 6620 345 3HAC027151 001 Revision T Copyright 2006 2018 ABB ...

Page 346: ...on Contents standard toolkit Rem Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm 1 Hex bit...

Page 347: ...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 Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found ...

Page 348: ...e procedures The tools may be ordered separately and are also specified directly in concerned instructions in the product manual Art no Qty Description 3HAC026597 001 Lifting tool Hoisting block Lifting chain used together with the hoisting block 3HAC15535 1 Support base and gear axis 1 3HAC15556 1 Lifting tool gearbox axis 1 3HAC025333 005 Lifting eye used together with lifting tool 3HAC 15556 1 ...

Page 349: ...ting 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 Product manual IRB 6620 349 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 7 Reference information 7 7 Lifting accessories and lifting ...

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Page 351: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 6620 351 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 8 Spare part lists 8 1 Spare part lists and illustrations ...

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Page 353: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 354: ...am IRB 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 354 Product manual IRB 6620 3HAC027151 001 Revision T Copyright 2006 2018 ABB All rights reserved 9 Circuit diagram 9 1 Circuit diagrams Contin...

Page 355: ...310 calibration scales 310 CalibWare 306 carbon dioxide extinguisher 21 cast iron disposal 335 changing oil axis 1 151 cleaning 173 climbing on robot 24 Cold environments 114 complete arm system replacement 202 connecting the robot and controller cabling 112 connection external safety devices 25 copper disposal 335 D damage to additional mechanical stop 141 damage to mechanical stop 139 danger lev...

Page 356: ...cement 253 motor axis 4 replacement 260 motor axis 5 replacement 265 motor axis 6 replacement 270 MoveAbsJ instruction 334 N nation specific regulations 17 negative directions axes 312 neodymium disposal 335 NiCad disposal 335 nodular iron disposal 335 O oil amount in gearboxes 149 disposal 335 type of oil 149 oil change axis 1 151 safety risks 37 oil level gearbox axis 6 131 gearbox axis 5 129 ge...

Page 357: ...usting 114 stability 65 standards 339 ANSI 340 CAN 340 EN 339 EN IEC 339 EN ISO 339 start of robot in cold environments 114 steel disposal 335 storage conditions 60 suspended mounting 91 symbols safety 39 synchronization position 315 sync marks 310 system integrator requirements 17 system parameter Gravity Alpha 92 Gravity Beta 91 T temperatures operation 60 storage 60 testing brakes 35 three posi...

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Page 360: ...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 Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC027151 001 Rev T en Copyright 2006 2018 ABB All rights reserved ...

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