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1.3.9 Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Note

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

Residual energy

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

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

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

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

Splashed oil may cause injury or fire.

Safe design

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

Dump valves should be used in case of emergency.

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

Product manual - IRB 6620LX

33

3HAC035737-001 Revision: P

© Copyright 2009-2018 ABB. All rights reserved.

1 Safety

1.3.9 Safety risks related to pneumatic/hydraulic systems

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Summary of Contents for IRB 6620LX

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

Page 2: ...Trace back information Workspace R18 2 version a18 Checked in 2018 11 20 Skribenta version 5 3 012 ...

Page 3: ...Product manual IRB 6620LX IRC5 Document ID 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instructions ...

Page 5: ...anual 40 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Robot transportation precautions 49 2 3 Unpacking 49 2 3 1 Pre installation procedure 53 2 3 2 Working range and type of motion 55 2 3 3 Risk of tipping stability 56 2 4 On site installation 56 2 4 1 Frame configurations 59 2 4 2 Lifting and securing the frame 66 2 4 3 Joining two frame t...

Page 6: ...4 10 Replacement of felt pinion 172 3 4 11 Replacing the lubricant cartridge and battery 173 3 5 Cleaning activities 173 3 5 1 Cleaning the IRB 6620LX 177 4 Repair 177 4 1 Introduction 178 4 2 General procedures 178 4 2 1 Performing a leak down test 179 4 2 2 Mounting instructions for bearings 181 4 2 3 Mounting instructions for seals 183 4 2 4 Cut the paint or surface on the robot before replacin...

Page 7: ...unters 320 5 5 Calibrating with Axis Calibration method 320 5 5 1 Description of Axis Calibration 323 5 5 2 Calibration tools for Axis Calibration 325 5 5 3 Installation locations for the calibration tools 327 5 5 4 Axis Calibration Running the calibration procedure 333 5 6 Calibrating with Calibration Pendulum method 334 5 7 Verifying the calibration 335 5 8 Checking the synchronization position ...

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Page 9: ...s of the IRB 6620LX Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information o...

Page 10: ... manual IRC5 IRC5 with main computer DSQC1000 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC16578 1 Operating manual Calibration Pendulum 3HAC050944 001 Operating manual Service Information System 3HAC051016 001 Application manual Additional axes and stand alone control ler 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC050948 001 Technical reference manual Syst...

Page 11: ...nger and Warning see Safety signals in the manual on page 38 New safety labels on the manipulators see Safety symbols on product labels on page 40 Revised terminology robot replaced with manipulator A This revision includes the following additions and or changes Updates in chapter Calibration Minor updates B Minor updates C This revision includes the following updates A new block about general ill...

Page 12: ...le holder carrier screw see Replacement of cable harness upper end on page 195 Added new sections to the manual Robot transportation precautions on page 48 Working range and type of motion on page 53 Robot cabling and connection points on page 116 Minor corrections G This revision includes the following updates The value for the system parameter Gamma Rotation is corrected see Setting the system p...

Page 13: ...elease R18 1 The following updates are made in this revision Information added about fatigue to Axis Calibration tool see Calibration tools for Axis Calibration on page 323 Added sections in General procedures on page 178 Safety restructured New spare part number brake release board was DSQC563 Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previ...

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

Page 15: ... 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 6620LX 15 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved Product documentation Continued ...

Page 16: ...mpleted 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: ...rried 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 respon...

Page 18: ...rking in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure that ...

Page 19: ...iew The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 6620LX 19 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 20: ...ishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 20 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 21: ...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 Product manua...

Page 22: ...roller 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 22 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 A...

Page 23: ...fety 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 purp...

Page 24: ...difications 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 ...

Page 25: ... 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 26: ...ore 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 m...

Page 27: ...n 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 28: ...anipulator 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 pre...

Page 29: ...isks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 70...

Page 30: ... 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 30 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 31: ... 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 s...

Page 32: ...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 32 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 3 8 H...

Page 33: ...e 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 an...

Page 34: ...s 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 34 Product manual IRB 6620LX 3HAC035737 001 Revision P Co...

Page 35: ...osion 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 a...

Page 36: ...on 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 rea...

Page 37: ...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 volu...

Page 38: ... 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 Warns for electrical hazards which could result in severe personal injury or death...

Page 39: ... conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRB 6620LX 39 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 40: ...ish 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 cr...

Page 41: ...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 Product manual IRB 6620LX 41 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights r...

Page 42: ...p over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 42 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 43: ... 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 Product manual IRB 6620LX 43 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...001242 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 44 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...at 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 Product manual IRB 6620LX 45 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Conti...

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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 6620LX is connected to power always make sure that the robot is connected to protecti...

Page 48: ...y compensation claim Method 1 recommended method Transportation according to method 1 is strongly recommended by ABB xx0800000030 Always follow these instructions when transporting an ABB robot according to method 1 Always remove the tool before transportation of the robot Always place the robot in the ABB recommended transport position described in section Risk of tipping stability on page 55 Alw...

Page 49: ...robot as specified in Weight robot on page 49 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 52 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 52 7 Before taking the robot to its installation site make sure that the site conforms to Loads...

Page 50: ...rce z F z Force Torque Z Torque X Y Z Torque Y Z X 418 xx1000000055 The table shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time Continues on next page 50 Product manual IRB 6620LX 3HAC035737 001 Revision...

Page 51: ...um tilt The value is recommended for optimal perform ance Note It may affect the manipulator life time to have a lower resonance frequency than recommended Minimum resonance frequency Due to foundation stiffness consider robot mass including equipment i For information about compensating for founda tion flexibility see Application manual Control ler software IRC5 section Motion Process Mode i The ...

Page 52: ...s robot The table shows the allowed operating conditions for the robot Value Parameter 5 C i Minimum ambient temperature 50 C Maximum ambient temperature Max 95 at constant temperat ure Maximum ambient humidity i At low environmental temperature 10 C a warm up phase is recommended to be run with the robot as with any other machine Otherwise there is a risk that the robot stops or run with lower pe...

Page 53: ... default working range for axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding the axis IRB6620LX 150 1 9 Reach m Handling capacity kg Robot Type 2 2 150 IRB 6620LX 150 1 9 xx0900000787 Continues on next page Product manual IRB 6620LX 53 3HAC035737 00...

Page 54: ...xx0900000786 54 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Working range and type of motion Continued ...

Page 55: ...s 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 xx0900000167 WARNING The robot is likely to be mechanically unstable if not secured to the foundation Product manual IRB 6620LX 55 3HAC035737 001 Revision P Copyright 2009 2018 ABB All ...

Page 56: ...tection oil serves as protection for the machine parts Do not remove the oil Configurations Two configurations are used for the IRB6620LX xx0900000226 Frame configuration for inverted mounting A Frame configuration for side assembly B Continues on next page 56 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 1 Fram...

Page 57: ...elivery At delivery the IRB 6620LX is divided in sections The sections and their weight are described in the figure below In this figure the sections are 12 m xx0900000275 Lower leg sections lifting weight aprox 1300 kg A Continues on next page Product manual IRB 6620LX 57 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 1 Frame configurati...

Page 58: ...ipulator lifting weight approx 600 kg D Sections to assembly For assembly information see Section A to B and A to C described in Assembling the frame supports on page 62 Section B to C described in Joining frames on page 66 58 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 1 Frame configurations Continued ...

Page 59: ...334 Lift the frame supports 1 4 and place them in an approximate position 1 Lift frame 5 and place it on top of frame supports 1 and 2 2 Assemble all bolts and nuts 6 7 and tighten them 3 Lift frame 8 and place it on top of frame supports 3 and 4 4 Assemble all bolts and nuts 9 10 and tighten them 5 Join the two tracks 11 and tighten the assembly see section Joining two frame tracks on page 66 mor...

Page 60: ...eighs 1300 kg all lifting equipment used must be sized accordingly Continues on next page 60 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Lifting and securing the frame Continued ...

Page 61: ...crew D Lifting protection E DANGER Always use lifting protective plates against sharp corners CAUTION The support frame weigh up to 5400 kg all lifting equipment used must be sized accordingly Continues on next page Product manual IRB 6620LX 61 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Lifting and securing the frame Continued ...

Page 62: ...ers 2 Assembling the frame supports xx0900000233 Nut M24 A Screw M24 x 70 with washer B Tightening torque 725 Nm Continues on next page 62 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Lifting and securing the frame Continued ...

Page 63: ...ht M24 screw 1 Tightening torque 725 Nm Assemble the frame support to the frame using the sixteen M24 x 120 screws use the distance plates 2 Continues on next page Product manual IRB 6620LX 63 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Lifting and securing the frame Continued ...

Page 64: ...elling screw to adjust the height of each frame support Use a water leveler to get the frame horizontal 1 Drill holes for the anchor bolts use drills according to the table above 2 Assemble the anchor bolts according to the manufac turer instructions 3 Continues on next page 64 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commis...

Page 65: ...ll holes for the anchor bolts and fasten the plate to the floor 1 Assemble and fasten the anchor bolts according to the manufacturer instructions 2 Use the ground levelling screw to adjust the height of each frame support Use a water leveler to get the frame horizontal 3 When the support stands are positioned weld the weld nuts according to the table above 4 Product manual IRB 6620LX 65 3HAC035737...

Page 66: ... bar 1 A Track bar 2 B Washer C Distance plate D Centering bolt E Screws M20 x 105 F Tightening torque 600 Nm Note Action xx0900000349 Move two sections together 1 Continues on next page 66 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Joining two frame tracks ...

Page 67: ... D Weld 2 Tightening torque 600 Nm Fix the frames using the two centering bolts and the twelve attachment screws 3 Continues on next page Product manual IRB 6620LX 67 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Joining two frame tracks Continued ...

Page 68: ...e Action xx0900000362 Use a gauge B to adjust the gear racks A 1 Tightening torque 83 Nm Tighten the gear racks 2 Continues on next page 68 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Joining two frame tracks Continued ...

Page 69: ...X and Y Desired value X Y 0 02mm 3 A Guidance transition B Measurement tool Product manual IRB 6620LX 69 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Joining two frame tracks Continued ...

Page 70: ...bot Fork lift device set The fork lift device accessory is fitted to the robot as shown in the figure xx0900000168 Lifting and turning tool 3HAC034648 001 A Fork lift pocket B 2x screw M12x30 C 2x screw M12x20 D Continues on next page 70 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 Lifting robot with fork lif...

Page 71: ...age 348 Standard toolkit Shipping position The illustration shows the position of the robot when lifting it with a fork lift xx0900000169 Continues on next page Product manual IRB 6620LX 71 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 Lifting robot with fork lift accessory Continued ...

Page 72: ...upply to the robot air pressure supply to the robot Before entering the robot working area 2 xx0900000170 Fit the turning tool 3HAC034648 001 3 A Turning tool 3HAC034648 001 B 2x screw M12x20 C 2x screw M12x30 Insert fork lift forks into the pock ets 4 CAUTION Lifting the robot with fork lift shall only be done with all four fork lift pockets fitted If lifting with fewer than four fork lift pocket...

Page 73: ...t with low speed 7 WARNING Personnel must not under any cir cumstances be present under the suspended load 8 For more information see the sec tion Lifting the robot with lifting and turning tool on page 74 9 Product manual IRB 6620LX 73 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 Lifting robot with fork lift accessory Continued ...

Page 74: ...lifting and turning of the IRB 6620LX A B D C xx0900000243 Upper lifting beam A Lower lifting beam B Locking screws C Lifting eye D Continues on next page 74 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool ...

Page 75: ...ipment pallet E CAUTION The IRB 6620LX shipment pallet is prepared for this specific use and is not a standard pallet do not use a standard pallet as a transportation or storage stand for the robot Continues on next page Product manual IRB 6620LX 75 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turnin...

Page 76: ...B 2x screw M12x20 C 2x screw M12x30 Attach a overhead crane to the upper lifting beam 3 Note Use a suitable chain block for minimum lifting weight 500 kg and with chain length minimum 3 m Attach a chain block and a lifting eye in the robot up per arm 4 Tighten the chain block 5 Lift the robot 6 Continues on next page 76 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB Al...

Page 77: ...s balanced 7 xx0900000254 Fit a lifting eye in the robot foot 8 Continues on next page Product manual IRB 6620LX 77 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 78: ...ing screws on the lifting tool shown in figure in the sec tion Lifting the robot with lifting and turning tool on page 74 10 Continues on next page 78 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 79: ...0374 Strap the cables to the base flange 12 xx0900000267 Remove A Grease reservoir B Motor cover Fit C Guide sleeves 13 Continues on next page Product manual IRB 6620LX 79 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 80: ...en them 16 xx0900000245 Do the electrical connec tions R1 MP R1 SMB as in figure A Then follow the connec tions as R1 MP1and R1 FB1 in figure B Fit the cover on the back of the axis 1 motor Fit the cable gland Fit the connection plate C for the connectors R1 MP R1 SMB onto the carriage 17 Described in the section Checking the synchronization position on page 335 Calibrate the robot 18 Continues on...

Page 81: ...ss CAUTION It is possible to damage the cable harness depend ing on from which side the forklift is used 2 xx0900000244 Use a forklift for easier mounting of the lifting and turning tool 3 Continues on next page Product manual IRB 6620LX 81 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Co...

Page 82: ... B Screws 2x M12x20 C Screws 2x M12x30 xx0900000169 Jog the robot into lifting position 5 Continues on next page 82 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 83: ...service work on ro bots on page 23 6 xx0900000245 Disconnect the electrical connections R1 MP R1 SMB A in fig ure Dismount the cover on the back of the motor axis 1 and disconnect R1 MP1and R1 FB1 B in figure Dismount the cable gland Dismount the connection plate C for the connectors R1 MP R1 SMB from the carriage 7 Continues on next page Product manual IRB 6620LX 83 3HAC035737 001 Revision P Copy...

Page 84: ...The lifting weight is 640 kg 10 Remove the six 6 attach ment screws 11 WARNING Personnel must not un der any circumstances be present under the suspen ded load 12 Dismantle procedure 90 Information Action Jog the robot axis to a position suitable for dis mantling and mounting the turning tool 1 Continues on next page 84 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB Al...

Page 85: ... B Screws 2x M12x20 C Screws 2x M12x30 xx0900000382 Jog the robot into lifting position 3 Continues on next page Product manual IRB 6620LX 85 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 86: ...SMB A in fig ure Dismount the cover on the back of the motor axis 1 and disconnect R1 MP1and R1 FB1 B in figure Dismount the cable gland Dismount the connection plate C for the connectors R1 MP R1 SMB from the carriage 5 CAUTION This step is essential to prevent the overhead crane from damaging the carriage bearings Loosen the six 6 attach ment screws A until you see a gap between the ro bot and t...

Page 87: ...move the six 6 attach ment screws 9 WARNING Personnel must not un der any circumstances be present under the suspen ded load 10 Continues on next page Product manual IRB 6620LX 87 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 88: ...is possible to use the forklift or using a second chain block 11 Continues on next page 88 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 89: ...lock to lower the robot completely 12 Continues on next page Product manual IRB 6620LX 89 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 90: ...th minimum 3 m A Lifting eye B Lifting beam upper C Lifting chains D Turning the robot Information Action Attach the upper beam to the lower beam using the lifting chains 1 Continues on next page 90 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 91: ...oot attachment hole and at tach the chain block 3 Loosen the fork locking screws 4 Use the chain block to lift and balance the robot 5 xx0900000374 Remove the straps from the cables on the base flange 6 Continues on next page Product manual IRB 6620LX 91 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and t...

Page 92: ... the pressure on the chain block 9 When the pressure is gone remove the chain block from the robot foot 10 Remove the lifting eye 11 Continues on next page 92 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 93: ...eye in the robot upper arm 12 Continues on next page Product manual IRB 6620LX 93 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 94: ... robot foot is horizontal 13 xx0900000252 Fit the robot onto the ship ment pallet 14 94 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Lifting the robot with lifting and turning tool Continued ...

Page 95: ...elease unit is located as shown in the figure Brake release at base The figure below shows the unit located at the base xx0900000142 Internal brake release unit with push buttons A Continues on next page Product manual IRB 6620LX 95 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Manually releasing the brakes ...

Page 96: ...es If the robot is not connected to the control ler power must be supplied to the connect or R1 MP according to the section Supply ing power to connector R1 MP on page 97 1 DANGER When releasing the holding brakes the ro bot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot arm 2 Release the holding brake on a particular robot axis by p...

Page 97: ...e 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 Product manual IRB 6620LX 97 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Manually releasing the brakes Continued ...

Page 98: ...ttachment 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 Continues on next page 98 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 200...

Page 99: ...s the hole configuration used when securing the robot xx0900000172 Product manual IRB 6620LX 99 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 7 Orienting and securing the robot Continued ...

Page 100: ...ements on the foundation are described in Requirements foundation on page 51 System parameters Note The mounting angle must be configured correctly in the system parameters so that the robot system can control the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functio...

Page 101: ...arameters Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage track motion Mounting angles and values The following values are applicable for the IRB 6620LX Gamma Rotation Gravity Alpha Position of the robot 1 570796 3 141592 Suspended 1 570796 1 570796 Wall Defining the parameter in the IRC5 software The value of the system parameters that define the mou...

Page 102: ...ted by the robot user Make sure the required mounting holes are accessible when planning the robot cell Note All equipment and cables used on the robot must be designed and fitted not to damage the robot and or its parts Continues on next page 102 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 9 Fitting equipment...

Page 103: ...he mounting holes available for fitting extra equipment on the upper arm xx0600002941 Continues on next page Product manual IRB 6620LX 103 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 9 Fitting equipment on robot Continued ...

Page 104: ...se screws with quality 12 9 Standard screws with quality 8 8 may be used when fitting other equipment to the mounting holes 104 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 9 Fitting equipment on robot Continued ...

Page 105: ...t and startup E chainsystems IGUS on myABB business portal www myportal abb com or visit the homepage www gudel com Product manual IRB 6620LX 105 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 10 Installing the guide trough ...

Page 106: ...allation site To move the chain from storage to track use one of the methods described in this section Method 2 requires an overhead crane Required equipment Note Art no Equipment Quantity depends on track motion length Lifting slings standard Required if using lifting method 1 Required if using lifting method 2 Lifting sling extra wide 50 mm Overhead crane Method 1 lifting the cable chain that is...

Page 107: ...oved before the cable chain is placed inside the tray 5 Lower the fixed and movable ends first then continue lowering bit by bit until the complete chain is fitted into the tray while at the same time removing the lifting slings one by one Method 2 lifting the cable chain that is rolled This procedure requires an overhead crane Note Action CAUTION The complete cable chain weighs 8 15 kg meter depe...

Page 108: ...er to keep the correct length for long chains that are to be rolled the strapping plate as well as the first cover and clips are removed Refit these parts during installation 6 Installing the cable chain into the tray How to install the cable chain into the tray is described in Refitting the energy chain on page 293 For more information see Installation guide Gliding applications IGUS on myABB bus...

Page 109: ...ng the speed run to each end position Check for sufficient e chain length e chain must not be under mechanical stress or taught Check complete e chainsystem is free from foreign objects or interfering edges For more information see Transport and startup E chainsystems IGUS at myABB Business Portal www myportal abb com or visit the homepage www gudel com Product manual IRB 6620LX 109 3HAC035737 001...

Page 110: ...obot 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 110 Pr...

Page 111: ... legs in combination with high legs are more unstable The floor stability and attachment of the lower legs are also important factors The performance will in general be better when the robot is at a position close to a leg See Product specification IRB 6620 and Product specification Linear Axis Reduce the acceleration The instruction AccSet can be used in the RAPID program to temporarily reduce th...

Page 112: ...TuneMaster is a good tool for finding the optimal value of TUNE_DF TuneMaster is included in the RobotWare distribution The argument Type in the instruction TuneServo can be defined as TUNE_DH to improve the smoothness of the robot path by decreasing the effective bandwidth Using TUNE_DH affects the path in corner zones increasing the cycle time in fine points but not along the entire path For mor...

Page 113: ...n 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 6620LX 113 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 4 15 Signal lamp option ...

Page 114: ...nnected either to the robot controller or to a PLC Code must be written to handle the signal Setting up the lubrication interval The general recommendation is to start with a time interval of 150 hours or a length interval of 100 km for the lubrication These values are to be used for normal room conditions regarding temperature humidity and dust If the conditions are more severe shorter intervals ...

Page 115: ...t value twice If no response has been received from the sensor after 5 pulses and 25 min an error has occurred 1 2 0 5min 10min 15min 20min 25min 30min 0 5min 10min 15min 20min 25min 30min 10sek A B A B xx1200001040 Start 0 Normal case 1 Error occured 2 Motor signal A Sensor signal B Further information System functions mechanical connection signal diagram function description maintenance informat...

Page 116: ... References 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 Connection point cabinet Description Cable sub category R1 MP XS1 Transfers drive power from the drive units in the control cabinet to the robot motors Robot cable power R1 SMB XS2 Transfers resolver data from and power supply to th...

Page 117: ...imes the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Product manual IRB 6620LX 117 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Robot cabling and connection points Continued ...

Page 118: ...egulated 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 W...

Page 119: ...ctions 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 the...

Page 120: ...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 121: ...leaning For more information see the docu mentation Operating manual TM O Sizes 40 90 Güdel or Operating manual TM O 1 4 Güdel on myABB business portal www mypo rtal abb com depending on produc tion year or visit the homepage www gudel com 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 mo...

Page 122: ...ler turned on until the battery is to be replaced See the replacement instruction for more details iv The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot powered off is less than 2 months The typical lifetime of a new battery is 36 months if the robot is powered off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extend...

Page 123: ...ystems IGUS on myABB busi ness portal www mypo rtal abb com or visit the homepage www gudel com Before start up Installed e chain Inspection For more information see Transport and star tup E chainsystems IGUS on myABB busi ness portal www mypo rtal abb com or visit the homepage www gudel com Before start up and periodically Cables and hoses Inspection For more information see Transport and star tu...

Page 124: ...ii Cable harness Extreme usage iii 40 000 hours Gearboxes iv i Examples of normal usage in regard to movement most material handling applications ii Severe chemical or thermal environments or similar environments can result in shortened life expectancy iii Examples of extreme usage in regard to movement press tending very severe palletizing applications major use of axis 1 movement iv The SIS for ...

Page 125: ...TM O Sizes 40 90 Güdel or Operating manual TM O 1 4 Güdel on myABB business portal www mypo rtal abb com depending on production year or visit the homepage www gudel com Product manual IRB 6620LX 125 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting the oil level in axis 1 gearbox ...

Page 126: ...al center underneath the motor attachment xx0900000144 Oil plug filling A Oil plug inspection B Oil plug draining C Required equipment Note Art no Equipment etc Note Do not mix with other oils See Type and amount of oil in gear boxes on page 143 Lubricating oil Content is defined in section Standard tools on page 348 Standard toolkit Continues on next page 126 Product manual IRB 6620LX 3HAC035737 ...

Page 127: ...Before entering the robot working area 2 This is a precaution to reduce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 3 Shown in the figure Location of gear box on page 126 Open the oil plug filling and inspection 4 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...

Page 128: ...ls See Type and amount of oil in gearboxes on page 143 Lubricating oil Content is defined in section Standard tools on page 348 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 128 Product manual IRB 6620LX 3HAC035737 001 Revision P ...

Page 129: ...tering 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 128 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 6...

Page 130: ...nt of oil in gearboxes on page 143 Lubricating oil Content is defined in section Stand ard tools on page 348 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 130 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018...

Page 131: ...bot 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 130 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 total...

Page 132: ...l in gearboxes on page 143 Lubricating oil Content is defined in section Standard tools on page 348 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 132 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All ...

Page 133: ...sure supply to the robot Before entering the robot working area 4 This is a precaution to reduce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 5 Shown in the figure Location of gearbox on page 132 Open the oil plug filling and inspection 6 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 143 Adjust...

Page 134: ...equired 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 pag...

Page 135: ...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 for...

Page 136: ...n the section Filling oil axis 6 on page 162 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 12 136 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 6 Inspecting the oil level in axis 6 ge...

Page 137: ...ning sign symbol of a flash located on motor cover 4 pcs B Warning label concerning brake release C Warning label concerning risk of tipping D Instruction label concerning lifting E Label for calibration F Serial no from rating label G Required tools and equipment Visual inspection no tools are required Continues on next page Product manual IRB 6620LX 137 3HAC035737 001 Revision P Copyright 2009 2...

Page 138: ...orking 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 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the information labels Continued ...

Page 139: ...n of mechanical stop pin The axis 1 mechanical stop is located as shown in the figure xx0900000176 Mechanical stop ax 1 A Required equipment Visual inspection no tools are required Continues on next page Product manual IRB 6620LX 139 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the axis 1 mechanical stop pin ...

Page 140: ...fore 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 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the axis 1 mechanical stop pin ...

Page 141: ...tandard 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 Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note Action Check that signal lamp is lit when motors are put in operation MOTORS ON 1 Continues on next page Product manual...

Page 142: ...s specified in Required equipment on page 141 If the lamp is not lit trace the fault by Checking whether the signal lamp is broken If so replace it Checking cable connections Checking the cabling Replace cabling if a fault is detected 3 142 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting signal lamp Continued ...

Page 143: ...rboxes available for registered users on 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 lat...

Page 144: ... axis 6 F Equipment Note Equipment Includes 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 144 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes Continued ...

Page 145: ...gearbox is located between the frame and base Oil plugs are shown in the figure xx0900000148 Vent screw A Oil plug filling B Oil plug draining C Continues on next page Product manual IRB 6620LX 145 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox ...

Page 146: ... Content is defined in section Standard tools on page 348 Standard toolkit Changing oil axis 1 Use this procedure to drain oil in gearbox axis 1 xx0900000210 Gearbox axis 1 A Attachment screws gearbox B AC motor C Attachment screws motor D Flank E Clutch locking screw F Clutch G Continues on next page 146 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserv...

Page 147: ... a dial indicator to make sure that the carriage re mains in position when refitting the gearbox 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Remove R2 MP1 and R2 FB1 connectors from the motor 4 Continues on next page Product manual IRB 6620LX 147 3HAC035737 001 Revision P Copyright 2009 2018 ABB All...

Page 148: ... total amount is detailed in Type of lubrication in gearboxes on page 143 Fill the gearbox with the correct amount of lubricating oil 9 Refit the oil plug filling 10 Tightening torque 83 Nm Refit the gearbox to the carriage using the four attachment screws M12x180 11 Refit R2 MP1 and R2 FB1 to the motor 12 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the...

Page 149: ...il types See Type and amount of oil in gearboxes on page 143 See Type and amount of oil in gearboxes on page 143 Lubricating oil Capacity 5 000 ml Oil collecting vessel Content is defined in section Special tools on page 349 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 348 Standard toolkit Continues on next page Product manual IRB 6620LX 149 3HAC03573...

Page 150: ...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 36 3 Vessel capacity is specified in Required equipment on page 149 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 o...

Page 151: ...spection 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 143 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 126 4 Note Don t mix Kyodo Yushi TMO 150 with other oil types 5 Tightening torque 24 Nm Refit the oil plug 6 Product manual IRB 6620LX 151 3...

Page 152: ...ment etc Note Do not mix with other oil types See Type and amount of oil in gear boxes on page 143 See Type and amount of oil in gearboxes on page 143 Lubricating oil Content is defined in section Special tools on page 349 3HAC021745 001 Oil exchange equipment Capacity 3 000 ml Oil collecting vessel Continues on next page 152 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ...

Page 153: ...ad the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 36 2 Remove the oil plug filling 3 Shown in the figure Location of gearbox on page 152 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 work with gearbox lubricants o...

Page 154: ...afety information in the section Safety risks during work with gearbox lubricants oil or grease on page 36 2 Shown in the figure Location of gearbox on page 152 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 143 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspecting t...

Page 155: ...f oil in gear boxes on page 143 See Type and amount of oil in gearboxes on page 143 Lubricating oil Content is defined in section Special tools on page 349 3HAC021745 001 Oil exchange equipment Capacity 6 000 ml Oil collecting vessel Content is defined in section Standard tools on page 348 Standard toolkit Continues on next page Product manual IRB 6620LX 155 3HAC035737 001 Revision P Copyright 200...

Page 156: ...the oil from the gearbox into a vessel by opening the oil plug draining 5 Vessel capacity is specified in Re quired equipment on page 155 This is detailed in section Synchroniz ation marks and synchronization pos ition for axes on page 303 Run 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 ...

Page 157: ...5 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section In specting the oil level in axis 4 gearbox on page 130 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 143 Tightening torque 24 Nm Refit the oil plug filling 4 Product manual IRB 6620LX 157 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights...

Page 158: ... in gearboxes on page 143 See Type and amount of oil in gearboxes on page 143 Lubricating oil Content is defined in sec tion Special tools on page 349 3HAC021745 001 Oil exchange equipment Capacity 4 000 ml Oil collecting vessel Content is defined in sec tion Standard tools on page 348 Standard toolkit Continues on next page 158 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 20...

Page 159: ...n in the figure Location of gearbox on page 158 Drain the oil from the gearbox by opening the oil plug draining 5 Vessel capacity is specified in Re quired equipment on page 158 Tightening torque 24 Nm Refit the oil plug draining 6 Filling 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 k...

Page 160: ...ox with clean lubricating oil The correct oil level is detailed in section Inspect ing the oil level in axis 5 gearbox on page 132 4 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 143 Tightening torque 24 Nm Refit the oil plug filling 5 160 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Mainte...

Page 161: ...349 3HAC021745 001 Oil exchange equip ment Vessel capacity Oil collecting vessel 500 ml Content is defined in section Standard tools on page 348 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 161...

Page 162: ...the kit is specified in Required equipment on page 161 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 gearbox...

Page 163: ... 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 134 Inspect the oil level Product manual IRB 6620LX 163 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axis 6 gearbox Continued ...

Page 164: ...grease Lubricant Grease gun Standard tools 2 000 h lubrication procedure Information Action Remove all 12 covers 1 Manually press the grease using a grease gun into each lubrica tion nipple 2 Refit all 12 covers 3 164 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 8 Lubrication of ball bearings and surface rollers ...

Page 165: ... months For an SMB board with 2 pole battery contact the typical lifetime of a new battery is 36 months if the robot is powered off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries Safety ri...

Page 166: ... B C D1 E F G H D2 xx0900000151 Attachment screws A SMB BU unit complete B Velcro strap C Battery pack 2 pole battery contact D1 Battery pack 3 pole battery contact D2 Continues on next page 166 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 9 Replacing the SMB battery Continued ...

Page 167: ... lists on page 351 Battery pack Content is defined in section Standard tools on page 348 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 updating of the revolution counter Move the robot to its calibration position 1 DANGER Turn off all electric power supply hydrau...

Page 168: ... air pressure supply to the robot before entering the robot working area 1 xx0200000023 2 WARNING The unit is sensitive to ESD Before handling the unit please read the safety information in the sec tion The unit is sensitive to ESD on page 31 Art no is specified in Required equipment on page 167 Reconnect the battery cable to the SMB battery pack and secure it with the velcro strap 3 Shown in figu...

Page 169: ...ing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 6 Product manual IRB 6620LX 169 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 9 Replacing the SMB battery Continued ...

Page 170: ...piece B Lubrication pinion C O ring D Chamber E Fixing bolts F Washer G Lubrication fitting H Car plate I Continues on next page 170 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 10 Replacement of felt pinion ...

Page 171: ...c ation 2 F in figure Remove the two fixing bolts 3 Remove the lubrication pinion unit 4 A in figure Remove the four screws holding the dis tance piece 5 C D E in figure Remove the chamber o ring and lubrica tion pinion 6 Product manual IRB 6620LX 171 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 10 Replacement of felt pinion Continued ...

Page 172: ...stem manual Automatic lubrication system Güdel on myABB business portal www myportal abb com or visit the homepage www gudel com 172 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 4 11 Replacing the lubricant cartridge and battery ...

Page 173: ...o the manipulator before entering its work space Special points Special points to be observed are shown in the figure below xx0900000152 Continues on next page Product manual IRB 6620LX 173 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 5 1 Cleaning the IRB 6620LX ...

Page 174: ...Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot Always check that all protective covers are fitt...

Page 175: ...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 minI I Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus Wash or Foundry Prime ...

Page 176: ...if they have a crusty surface for example from dry release agents 176 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 3 Maintenance 3 5 1 Cleaning the IRB 6620LX Continued ...

Page 177: ...rform 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 341 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 sure ...

Page 178: ...e 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: ... 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: ...rted 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 66...

Page 181: ...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 foreign ...

Page 182: ...ly 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 co...

Page 183: ...2 001 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 6620LX 183 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights r...

Page 184: ... 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 jamm...

Page 185: ...f assembling the laser ad justment kit Attach the Calpoint laser on to the Calpoint multi mount 2 A part of assembling the laser ad justment kit The Calpoint multi mount is included in the Calpoint kit Attach the Calpoint multi mount on to the turning disc 3 Put a guide pin in the robot tool flange 4 xx1700001006 Attach the laser adjustment kit on to the robot tool flange 5 Tighten the conical scr...

Page 186: ...int is reached 4 xx1700001007 Mark a target where the laser point is aimed when the fine position has been reached 5 Carefully remove the laser adjustment kit from the robot Note Make sure not to change the position of the Cal point laser pointer in relation to the turning disc 6 Replacing the robot Note Action See Lifting the robot with lifting and turning tool on page 74 Replace the robot and up...

Page 187: ...rget in one direction and that will be the rotational direction for the robot foot to axis 1 carrier 4 Note It is possible that the laser point deviates from laser target in the non rotational direction to the extent that it is difficult to validate if the position is good in the rotational direction If that is the case then jog only axis 2 so that the laser point is as close as possible to the la...

Page 188: ...corresponds with the marked target 7 Repeat the steps until the laser point corresponds to the marked target 8 188 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing the robot Continued ...

Page 189: ...section Replacement of cable harness upper end on page 195 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 The figure shows the upper routing of the cable harness xx0900000161 Upper arm cable harness A Metal clamp lower arm 2 pieces B Cable bundle C Continues on next page Product manual IRB 6620LX 189 3HAC035737 00...

Page 190: ...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 values requires possibility to move the robot Read more about reference calibration for Axis Calibration in ...

Page 191: ...nnection Shown in the figure Location of cable harness axes 1 2 on page 189 Disconnect connectors R1 MP and R1 SMB on the connection plate base 5 Shown in the figure Location of cable harness axes 1 2 on page 189 Disconnect all connectors at motors 1 R2 MP1 R2 FB1 and 2 R2 MP2 R2 FB2 6 Shown in the figure Location of cable harness axes 1 2 on page 189 Remove the metal clamps on the frame securing ...

Page 192: ...through the cable guide in the center of the frame 10 Detailed in the section Replacement of cable harness upper end on page 195 Continue removal of the cable harness axes 3 6 11 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 189 Push the cable harness axes 1 2 carefully down through the cable...

Page 193: ... 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 189 Refit the top cover connection box 7 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 8 Axis Calibration is described in Calibrating with Axis Calibration method on page 320 General calibr...

Page 194: ...irst test run These are fur ther detailed in the section First test run may cause injury or damage on page 26 9 194 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of cable harness lower end axes 1 2 Continued ...

Page 195: ...ess 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 qualit...

Page 196: ...n 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 creat...

Page 197: ...o bot 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 189 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...

Page 198: ...rew 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 Attac...

Page 199: ...nect 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 t...

Page 200: ...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 o...

Page 201: ...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 Product manual IRB 6620LX 201 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of cable harness upper end Con...

Page 202: ...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 202 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of cable harness upper end Con...

Page 203: ...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 Product manual IRB 6620LX 203 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of cable ...

Page 204: ...ge 320 General calibration information is included in section Calibration on page 299 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 page26 21 204 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of cab...

Page 205: ...en 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 348 Standard toolkit These procedures incl...

Page 206: ...rking area 2 Remove any equipment fitted to the turning disk 3 See section Changing oil axis 6 gear box on page 161 Drain the axis 6 gearbox 4 Shown in the figure Location of turning disk on page 205 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 207: ...re 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 page344 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 161 Refill the axis 6 gearbox with oil 5 Refi...

Page 208: ...rming the first test run These are further detailed in the section First test run may cause injury or damage on page 26 7 208 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Continued ...

Page 209: ...ist 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 6620LX 209 3HAC035737 001 Revision P Copyright 2009 2018 ABB ...

Page 210: ...ant 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 ca...

Page 211: ...n page 195 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 209 Unscrew the eight attachment screws securing the wrist unit 9 Note Do not damage the cylindric al pin in the process Remove the wr...

Page 212: ...579 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 A...

Page 213: ...equirements 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 26 12 Product manual IRB 6620LX 213 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4 2 Replacement of wrist unit Continued ...

Page 214: ...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 214 Product manual IRB 6620LX 3HA...

Page 215: ...rence 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 321 If no previous reference values exist and no new reference values can be created...

Page 216: ...rocedure 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 6 Art no is specified in Required equipment on page 214 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 b...

Page 217: ... four screws inside the hole in the lower arm 11 Remove the complete upper arm and put it on the floor Let the upper arm lean on its side 12 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 218: ...box 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 248 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 219: ...ibration tools Recalibrate the robot 13 Axis Calibration is described in Calibrating with Axis Calibration method on page320 General calibration information is included in section Calibration on page 299 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 page26 14 Product manual ...

Page 220: ...B3537 1 Grease Instruction 3HAC026600 002 is enclosed 3HAC026597 001 Lifting tool Lifting chain Hoisting block Roundslings Always use in pairs Guiding pins Content is defined in sec tion Standard tools on page 348 Standard toolkit These procedures include references 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 instruct...

Page 221: ...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 321 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about referen...

Page 222: ... 4 Detailed in the section Replacement of cable harness upper end on page 195 Remove the cable harness axes 3 6 5 Let the cable harness hang loose without it getting dam aged in the proceeded removal procedure 6 Detailed in the section Replacement of the upper arm on page 214 Remove the upper arm 7 Secure the robot in upright position on the transportation plate 8 Secure the lower arm with a round...

Page 223: ...Lift the lower arm on to the guiding pins 5 Shown in the figure Location of lower arm on page 220 Refit the 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 o...

Page 224: ... on page 320 General calibration information is in cluded in section Calibration on page 299 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 26 13 224 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 4 4 Replacemen...

Page 225: ...2 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 6620LX 225 3HAC03...

Page 226: ...bot 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 31 3 Shown in the figure Location of SMB...

Page 227: ...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 6620LX 227 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 5 1 Rep...

Page 228: ...7 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 225 Put the SMB BU unit back into its box and refit the attachment screws 4 Detailed in section Updating revolution counters on page 314 Update the revolution counters 5 Con...

Page 229: ...orming the first test run These are further detailed in the section First test run may cause injury or damage on page 26 6 Product manual IRB 6620LX 229 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 5 1 Replacement of SMB unit Continued ...

Page 230: ... DSQC633 F Brake 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 3HAC065020 001 Brake release board Content is defined in section Standard tools on page 348 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references t...

Page 231: ...itting 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 shor...

Page 232: ...n the SMB cover is refitted 3 Shown in the figure Location of brake release board on page 230 Art no is specified in Required equip ment on page 230 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 releas...

Page 233: ... 314 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 26 11 Product manual IRB 6620LX 233 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the brak...

Page 234: ...ystems on page 33 Risks associated with live electric parts on page 29 Safety risks during installation and service work on robots on page 23 Location of ball bearings xx0900000440 Tap screw A Tap B Support roller C Roller holder D Cover E Locking screw F Flange G Screw H Continues on next page 234 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Re...

Page 235: ...move the locking screw 3 Remove the cover 4 Remove the complete roller holder 5 Remove the tap screw and tap holding the support roller 6 Refitting Note Action Fit a new support roller on to the roller holder 1 Adjust the roller holder maximal open and lock it temporary using the locking screw Refit the complete roller holder 2 Adjust the support roller using a gauge 3 Refit the cover 4 Refit the ...

Page 236: ...ation method as used at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant Location of motor The motor axis 1 is located as shown in the figure below xx0900000216 Continues on next page 236 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 6 1 Replacement of ...

Page 237: ...ion method for the robot Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Cal ibration Required if Axis Calibration is the valid calibration method for the robot These procedures include refer ences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below See chapter Circuit diagram o...

Page 238: ...bout reference calibration for Axis Calibration in Reference calibration routine on page 321 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 cab...

Page 239: ... attach ment screw holes to press out the motor if required 2 For elastomer coupling see Oper ating manual Toploader Güdel Art no is specified in Required equipment on page 237 Always use the removal tools in pairs For multi tooth coupling see Ser vice manual Gearbox unit HPG Güdel If the motor is to be replaced with a new spare part move the coupling to the new motor as detailed in the gearbox se...

Page 240: ...omer coupling see Oper ating manual Toploader Güdel Following is only additional information to the pro cedure given in the gearbox service manual Fasten all motor attachment screws cross wise Tightening torque 26 Nm Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the cal ibration tools Recalibrate the robot 5 Axis Calibration is described in Calibrating wi...

Page 241: ...achment holes 4 pcs B R2 FB2 C R2 MP2 D Required equipment Note Art no Spare part no Equipment etc See Spare part lists on page 351 Motor including pin ion Must be replaced when re assembling motor 21522012 430 O ring Continues on next page Product manual IRB 6620LX 241 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 6 2 Replacement of motor axis 2 ...

Page 242: ...bration Required if Axis Calibration is the valid calibration method for the robot These procedures include references 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...

Page 243: ...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 motor The procedure below details how ...

Page 244: ...re supply to the robot air pressure supply to the ro bot Before entering the robot working area 3 Detailed in the section Changing oil axis 2 gear box on page 149 Drain the oil from gearbox axis 2 4 Remove the cover on top of the mo tor by unscrewing its four attach ment screws 5 Shown in the figure Location of motor on page241 Remove the cable gland cover at the cable exit by unscrewing its two a...

Page 245: ...1 Art no is specified in Required equipment on page 241 If required press the motor out of position by fitting the removal tool motor to the remaining motor attach ment holes 11 Shown in the figure Location of motor on page241 Always use the removal tools in pairs CAUTION The motor weighs 38 kg All lifting equipment used must be sized ac cordingly 12 Make sure the motor pinion does not get dam age...

Page 246: ...41 CAUTION The motor weighs 38 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 Make sure that the motor is turned the right direction that is the cables facing Art no is specified in Required equip ment on page 241 xx0200000165 Use the rotation too...

Page 247: ...etailed in Performing a leak down test on page 178 Perform a leak down test 14 Detailed in the section Changing oil axis 2 gearbox on page 149 Refill the gearbox with oil 15 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 16 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 320 Ge...

Page 248: ...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 Ro...

Page 249: ...g 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 previous refere...

Page 250: ...ing oil axis 3 gear box on page 152 Drain the oil from gearbox axis 3 3 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the ro bot Before entering the robot working area 4 Remove any equipment hindering access to motor axis 3 5 Remove the cover on top of the motor by unscrewing its four attach ment screws 6 Continues on next page...

Page 251: ...ress the motor out of position by fitting removal tool motor to the re maining motor attachment screw holes 11 Always use the removal tools in pairs Art no is specified in Required equipment on page 248 xx0900000196 Apply the lifting tool motor axis 2 3 4 to the motor 12 CAUTION The motor weighs 25 kg All lifting equipment used must be sized ac cordingly 13 Lift the motor to get the pinion away fr...

Page 252: ...ified in Required equipment on page 248 Fit the two guide pins in the two lower motor at tachment holes 4 Shown in the figure Location of mo tor on page 248 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 lift...

Page 253: ...ure 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 248 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 l...

Page 254: ...ming the first test run These are further detailed in the section First test run may cause injury or damage on page 26 20 254 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 6 3 Replacement of motor axis 3 Continued ...

Page 255: ... 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 rele...

Page 256: ...ols 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 257: ...uired press the motor out of position by fitting removal tool motor to the motor attachment screw holes 9 Always use the removal tools in pairs Lift the motor to get the pinion away from the gear and disconnect the brake release voltage 10 Make sure the motor pinion is not dam aged Remove the motor by gently lifting it straight out 11 Refitting motor axis 4 The procedure below details how to refit...

Page 258: ... pins 7 Secure the motor with four attachment screws and plain washers 8 Disconnect the brake release voltage 9 Reconnect all connectors beneath the motor cover 10 Make sure the cover is tightly sealed Refit the cover on top of the motor with its four attachment screws 11 Shown in the figure Location of motor on page 255 Refit the cable gland cover at the cable exit with its two attachment screws ...

Page 259: ...ming the first test run These are further detailed in the section First test run may cause injury or damage on page26 16 Product manual IRB 6620LX 259 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 6 4 Replacement of motor axis 4 Continued ...

Page 260: ...rt 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 12340011...

Page 261: ...ols 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 t...

Page 262: ... in the figure in section Loca tion of motor on page 260 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 260 Pull the cable ...

Page 263: ...tor R2 MP5 in the motor pin 2 pin 5 Art no is specified in Required equip ment on page 260 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 an...

Page 264: ... 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 320 General calibration information is in cluded in section Calibration on page 299 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 265: ... 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 Product manual IRB 6620L...

Page 266: ...xis 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 th...

Page 267: ...o 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 270 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 Move the robot to a...

Page 268: ...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 270 Note Action Art no is specified in Required equipment on page 265 Make sure the o ring on the circ...

Page 269: ...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 Axi...

Page 270: ... 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 accordin...

Page 271: ...ouse 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 268 9 Product manual IRB 6620LX 271 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 ...

Page 272: ... of the gear unit differs The differences are pointed out in the section Gearbox with multi tooth coupling xx0900000210 Gearbox axis 1 A Attachment screws gearbox B AC motor C Attachment screws motor D Flank E Clutch locking screw F Clutch G Continues on next page 272 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 1 Replacement of gearb...

Page 273: ... tools Required documents Note Document number Document Valid for multi tooth coupling 18014398746814859 001 Service manual Gearbox unit HPG Güdel Always download latest version from http www gudel com Valid for elastomer coupling 546181387 001 Operating manual Toploader Güdel Found on myABB business portal www myportal abb com Continues on next page Product manual IRB 6620LX 273 3HAC035737 001 Re...

Page 274: ... gearbox 4 For elastomer coupling see Operating manual Top loader Güdel Refitting the gearbox Note Action DANGER Turn off all electric power hydraul ic and pneumatic pressure sup plies to the robot 1 For multi tooth coupling see Service manual Gear box unit HPG Güdel Refit the gearbox to the carriage as detailed in the service manual for the gearbox 2 For elastomer coupling see Operating manual To...

Page 275: ...g manu al TM O 1 4 Güdel depending on production year Set the tooth flank backlash 5 For elastomer coupling see Operating manual Top loader Güdel Product manual IRB 6620LX 275 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 7 1 Replacement of gearbox 1 Continued ...

Page 276: ...AB3772 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 t...

Page 277: ...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 321 If no previous reference values exist a...

Page 278: ...in the oil from gearbox axis 2 5 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 6 Detailed in the section Replacement of cable har ness lower end axes 1 2 on page 189 Remove the cable harness axes 1 3 7 Let the removed part of the cable harness hang loose and take care not to dama...

Page 279: ...ft ing equipment used must be sized accordingly 14 Art no is specified in Required equipment on page 276 xx0900000114 Fit the lifting tool for lifting the gearbox in the uppermost hole and secure it with a roundsling 15 The figure shows IRB6640 Shown in the figure Location of gearbox axis 2 on page 276 Remove the attachment screws M12x60 24 pcs securing the gearbox to the frame 16 Remove the gearb...

Page 280: ...ccordingly 2 Art no is specified in Required equipment on page276 xx0900000114 Fit the lifting tool for lifting the gearbox in the uppermost hole of the gearbox and secure it with a roundsling 3 The figure shows IRB6640 Fit two guide pins in two of the attachment holes parallel to each other 4 Continues on next page 280 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB Al...

Page 281: ...of cable harness lower end axes 1 2 on page 189 Refit the cable harness axes 1 3 11 Detailed in the section Changing oil axis 2 gearbox on page 149 Fill the gearbox axis 2 with oil 12 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 13 Axis Calibration is described in Calibrating with Axis Calibration method on pag...

Page 282: ...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 348 Standard toolkit Continues on next page 28...

Page 283: ...rence 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 321 If no previous reference values exist and no new reference values can be created then reference calibration is not possible ...

Page 284: ...to the upper arm 8 Remove the gearbox and put it in a safe place 9 Refitting The procedure below details how to refit gearbox axis 3 Note Action xx0600003127 Make sure the o ring is fitted to the gearbox Lightly lubricate the o ring with grease 1 A O ring 3HAB 3772 92 CAUTION The gearbox weighs 51 kg All lifting equipment used must be sized accordingly 2 Art no is specified in Required equipment o...

Page 285: ...ed with the calibration tools Recalibrate the robot 9 Axis Calibration is described in Calib rating with Axis Calibration method on page 320 General calibration information is in cluded in section Calibration on page 299 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 26 ...

Page 286: ...Gearbox Must be replaced when reas sembling gearbox 3HAB3772 58 O ring For type 2 of the gearbox 3HAB3772 57 O ring 164 7x3 53 Must be replaced when reas sembling gearbox For type 2 of the gearbox 3HAB3772 64 O ring 150 0x2 0 Must be replaced when reas sembling gearbox For type 2 of the gearbox 3HAB3772 61 O ring 12 pcs 13 1x1 6 Must be replaced when reas sembling gearbox For lubricating the o rin...

Page 287: ...ssPack 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 reference values These ...

Page 288: ...x axis 6 3 Detailed in the section Removing turning disk on page 206 Remove the turning disc 4 Shown in the figure Location of gearbox on page 286 Remove the gearbox by unscrewing its attach ment screws 5 xx0200000220 If required apply M8 screws to the holes shown in the figure beside to press the gearbox out 6 A M8 holes for pressing out the gearbox xx1400001123 Foundry Plus Remove old Loctite 57...

Page 289: ...1 Article number is specified in Required equipment on page 286 xx0200000221 Make sure the o ring is fitted to the rear of the gearbox Lubricate the o ring with grease 2 A O ring gearbox axis 6 Detailed in the section Manually releasing the brakes on page 95 Release the holding brake of motor axis 6 3 xx1400001122 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 4 Continues on ...

Page 290: ... turning disc 7 Detailed in the section Performing a leak down test on page 178 Perform a leak down test 8 Detailed in the section Changing oil axis 6 gearbox on page 161 Refill the gearbox with oil 9 Pendulum Calibration is described in Oper ating manual Calibration Pendulum en closed with the calibration tools Re calibrate the robot 10 Axis Calibration is described in Calibrating with Axis Calib...

Page 291: ...nergy chain Lifting accessories Cable straps Content is defined in section Standard tools on page 348 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 6620LX 291 3HAC035737 001 Revision P Copyright 2009 2018 ABB Al...

Page 292: ...o the robot and for the linear axis 2 Disconnect all cables from the robot base cable interface 3 Disconnect all cables from the linear axis motor 4 Cut all cable straps using standard tools 5 Screws 4 pcs xx1500000840 Loosen the fixed end of the energy chain 6 Screws 4 pcs xx1500000838 Loosen the drivers end of the energy chain 7 Continues on next page 292 Product manual IRB 6620LX 3HAC035737 001...

Page 293: ...r more information see Installation guide Gliding applications IGUS on myABB business portal www myportal abb com or visit the homepage www gudel com Note Action Clean the energy chain and look for wear on the energy chain Wear on the energy chain can cause damage to the cables 1 Screws and nuts 4 pcs xx1500000841 Fit the mounting angle on the fixed end connection element using screws and nuts 2 S...

Page 294: ...he connection plates for individual strapping the cables should be secured in such a way that they can not move Connect all cables to the linear axis motor 7 Connect all cables to the robot base cable interface 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 9 See Te...

Page 295: ...he link of the carrier system as shown in the figure 2 Adjust the carrier position or alignment if needed 3 Adjust the position and length of cables and or hoses if needed 4 If adjustments are made repeat steps 1 to 4 5 Tighten all screws 6 The track is now ready to be powered up to full speed and duty cycle 7 Check the tightening torque on fastening screws after 500 cycles Adjust if needed Period...

Page 296: ... gudel com Layout of cables inside the energy chain Cable layout material handling with hydraulic hose xx1500000843 Power 2 1 Power 1 2 Air 3 Signal SMB 4 Profinet Power 5 Earth Güdel 6 Earth Leoni 7 Profinet 8 Lubrication 9 Continues on next page 296 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing cables in the energy chain ...

Page 297: ...r 5 Weld 2 6 Weld 3 7 Lubrication 8 Weld 1 9 KSR 10 Signal SMB 11 Profinet Power 12 Earth Leoni 13 Earth Güdel 14 Profinet 15 Product manual IRB 6620LX 297 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 4 Repair 4 8 2 Replacing cables in the energy chain Continued ...

Page 298: ...This page is intentionally left blank ...

Page 299: ...t 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 can...

Page 300: ... default Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots except IRB 6400R IRB 640 IRB 1400H and IRB 4400S Two different routines are available for the Calibration Pendulum method Calibration Pendulum II Reference calibration The calibration equipment for Calibration Pendulum is delivered as...

Page 301: ...may after calibration require modifications in the robot program and is therefore not recommended The calibration equipment Levelmeter 2000 for levelmeter calibration is ordered as separate parts for each robot and includes the Operating manual Levelmeter Calibration which describes the method and the different routines further References Article numbers for the calibration tools are listed in the...

Page 302: ...his will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are connected at the first installation The robot is rebuilt If the robot is rebuilt for example after a crash or when the reach...

Page 303: ...zation mark axis 1 optional location i A Synchronization mark axis 2 B Synchronization mark axis 3 C Synchronization mark axis 4 D Synchronization mark axis 5 E Synchronization mark axis 6 F i The location of the synchronization mark for axis 1 is optional and can be placed at a suitable position for the installation Product manual IRB 6620LX 303 3HAC035737 001 Revision P Copyright 2009 2018 ABB A...

Page 304: ... and so on Positive directions are shown in the graphic below Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions IRB6620 LX xx0900000140 304 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 2 2 Calibration move...

Page 305: ...method is used for calibration of axis 1 Note Article number Equipment From Güdel Drill gauge From Güdel Axis Calibration support block Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibra tion Required if Axis Calibration is the valid calibration method for the robot Travel directions for axis 1 xx0900000386 Continues on next page Product manual IRB 6620LX 305 ...

Page 306: ...as to be close to an end point with minimum 100 mm clearance between the dampers of the carriage and the end stop xx1600001123 A Minimum clearance 100 mm also other end of beam Manually run the robot axis 1 to an optional calibration position 1 Continues on next page 306 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 3 Calibration an...

Page 307: ...alibration pin on the carriage 2 Suspended xx1600001131 Continues on next page Product manual IRB 6620LX 307 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 3 Calibration and configuration of Joint Bound axis 1 Continued ...

Page 308: ...am The drill gauge fixes itself with magnets Place the gauge so that it points away from the end stop 4 Drill the fastening threads for the Axis Calibration sup port block screws 2 x M8 by using the drilling gauge 5 Continues on next page 308 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 3 Calibration and configuration of Joint Boun...

Page 309: ...g shims 7 Measurement 5 5 2 1 5 mm is defined by the correct location of the drill gauge xx1600001136 Check the measurement 5 5 mm and adjust within the tolerance of the M8 screws Tighten the M8 screws 8 xx1600001137 Drill two holes for dowel pins 2 x Ø6 H7 using the Axis Calibration support block for guidance 9 Dowel pins 2 x Ø6 M6x20 Insert the supplied dowel pins 10 Continues on next page Produ...

Page 310: ...re on page 327 Run the fine calibration routine for Axis Calibration to calibrate axis 1 3 xx0900000387 Fit the synchronization mark plate on the carriage B 4 Find the position of the syn chronization mark plate for the frame A by lining it up against the plate on the car riage 5 A Synchronization mark plate on the frame axis 1 B Synchronization mark plate on the carriage axis 1 60 xx0900000388 Fi...

Page 311: ...ning it up against the plate on the car riage 4 A Synchronization mark plate on the frame axis 1 B Synchronization mark plate on the carriage axis 1 60 xx0900000388 Fit the synchronization mark plate to the frame using a drill for M5 screw hole distance 60 mm 5 See Fine calibration procedure on FlexPendant on page 312 CAUTION This calibration method is only valid for axis 1 For all other axes the ...

Page 312: ...ed as detailed in the calibration instruction for the axis to be calibrated A dialog box is displayed warning that updating the revolution counters may change programmed robot positions Tap Yes to proceed Tap No to cancel Select the check box for the axis to calibrate 5 Tap Calibrate 6 A dialog box is displayed warning that calibration of the selected axes will be changed which cannot be undone Ta...

Page 313: ...oint Bound twice to change the value 9 Tap OK 10 Tap YES to restart the controller 11 When the controller is restarted it is possible to jog the robot to a suitable position for configuration of Upper Joint Bound and Lower Joint Bound 12 Jog the robot to a suitable positive position 13 Read the position from the Jogging window 14 Open the system parameters configuration editor again from the Contr...

Page 314: ...ator 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 314 P...

Page 315: ...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 Product manual IRB 6620LX 315 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 4 Updating revolut...

Page 316: ...d 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 317: ...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 Product manual IRB 6620LX 317 3HAC035737 001 Revision P Copyright 2009 2018 ABB All r...

Page 318: ...obotWare 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 318 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 4 Updating revolution counters Continued ...

Page 319: ... 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 may...

Page 320: ...able 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 inser...

Page 321: ...es 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 manipulat...

Page 322: ...t mounted at its working position not standing on a floor To calibrate a suspended or wall mounted robot with the fine calibration routine the robot must first be taken down and mounted standing on the floor 322 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 5 1 Description of Axis Calibration Continued ...

Page 323: ...s 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 a...

Page 324: ...olution 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 cavit...

Page 325: ...fixed calibration pins and or bushings Installed calibration tools are not shown A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows 1 xx1600000004 xx1600000002 Continues on next page Product manual IRB 6620LX 325 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 5 3 Installation locations for the calibratio...

Page 326: ...aling 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 326 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 5 3 Installation locations for the calibration tools Continued ...

Page 327: ...e 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 A...

Page 328: ...nt 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 329: ... the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 327 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 330: ...libration 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 synch...

Page 331: ...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 Product manual IRB 6620LX 331 3HAC035737 001 Revision P Copyright 2009 2018 ABB A...

Page 332: ...ction 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 001 332 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2...

Page 333: ...dulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools Product manual IRB 6620LX 333 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 5 Calibration 5 6 Calibrating with Calibration Pendulum method ...

Page 334: ...hange 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 303 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 fro...

Page 335: ...age 303 and Updating revolution counters on page 314 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 1...

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Page 337: ... 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 w...

Page 338: ... organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 338 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 339: ...ttery 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 6620LX 339 3HAC035737 001 Revision P Copyright 2009 2018 ABB All ...

Page 340: ...This page is intentionally left blank ...

Page 341: ...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 E...

Page 342: ... 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 14 342 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 7 Reference information 7 1 Applicable standards Continued ...

Page 343: ...9 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 6620LX 343 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 7 Reference information 7 2 Unit conversion ...

Page 344: ...ld 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 345: ...air 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 346: ...ing 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 4 346 Product manual IRB 6620LX 3HAC035737 001 Re...

Page 347: ...ory 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 610 kg All lifting accessories used must be sized accord ingly Product manual IRB 6620LX 347 3HAC035737 001 Revision P Copyright 2009 2018 ABB...

Page 348: ...n 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 349: ...tion Pendulum is used as default Note Art no Description Complete kit that also includes operating manual 3HAC15716 1 Calibration Pendulum toolkit Calibration equipment Axis Calibration The following table specifies the calibration equipment needed when calibrating the robot with the Axis Calibration method The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory Alway...

Page 350: ...ing 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 350 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 7 Reference information 7 7 Lifting accessories and lifting...

Page 351: ...ws 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 6620LX 351 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 8 Spare part lists 8 1 Spare part lists and illustrations ...

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Page 353: ... 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 2...

Page 354: ... 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 Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 354 Product manual IRB 6620LX 3HAC035737 001 Revision P Copyright 2009 2018 ABB All rights reserved 9 Circuit diagram 9 1 Circuit diagrams ...

Page 355: ...ot and controller cabling 116 connection external safety devices 24 copper disposal 337 D damage to mechanical stop 139 danger levels 38 dimensions upper arm 103 direction of axes 304 E enabling device 28 environmental information 337 equipment on robot 102 ESD damage elimination 31 sensitive equipment 31 expected life 124 external safety devices 24 extra equipment fastener quality 104 robot 102 u...

Page 356: ...24 protective wear 24 R region specific regulations 17 release brakes 21 replacement brake release board 230 gearbox axis 6 286 motor axis 1 236 motor axis 2 241 motor axis 3 248 motor axis 4 255 motor axis 5 260 motor axis 6 265 turning disk 205 replacing robot 185 SMB battery 165 requirements on foundation 51 responsibility and validity 17 revolution counters storing on FlexPendant 317 updating ...

Page 357: ...peration 52 storage 52 testing brakes 34 three position enabling device 28 tools Axis Calibration 349 Calibration Pendulum 349 for service 349 torques on foundation 50 troubleshooting oil spills 174 turning disk replacement 205 U updating revolution counters 314 upper arm dimensions 103 V validity and responsibility 17 velocity adjusting 118 verifying calibration 334 W wall mounting 100 weight 49 ...

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Page 360: ...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 3HAC035737 001 Rev P en Copyright 2009 2018 ABB All rights reserved Specifications subject to change without notice ...

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