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 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
2.4.15 Signal lamp (option) ................. 2.4.16 Automatic lubrication system ..............Electrical connections ..................2.5.1 Robot cabling and connection points ............Start of robot in cold environments ..............Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 6 Replacement of motor axis 2 ..............4.6.3 Replacement of motor, axis 3 ..............4.6.4 Replacement of motor, axis 4 ..............4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX ........... Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 7 Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare part lists Spare part lists and illustrations ................Circuit diagram Circuit diagrams ....................Index Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
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Page 9: Overview Of This Manual
ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 6620LX. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 Circuit diagrams Reference to the circuit diagram for the robot. References Following manuals are referred to from inside of the product manual. All referred manuals can be found via myABB Business Portal, www.myportal.abb.com. Reference Document ID Product specification - IRB 6620...
Page 11 This Güdel manual details the complete ABB toploader linear unit, including the elastomer coupling for the motor shaft. Since the manual is unique for ABB, Güdel does not provide it on their web site for download. This manual includes all...
Page 12 • Corrections due to updates in terminology for spare parts. • Maintenance interval for changing the axis-1 gearbox oil is changed. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 13 Published in release R18.2. The following updates are made in this revision: • Updated references. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 14: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 15 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 16: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 17: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
Page 18 Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.
Page 19: Protective Stop And Emergency Stop
1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 20: Safety Actions
1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 21: Emergency Release Of The Robot Axes
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 manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 22: Make Sure That The Main Power Has Been Switched Off
Wait for 5 minutes to let the capacitors discharge after the power has been switched off. DANGER Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 23: Safety Risks
Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 24 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.
Page 25: Moving Robots Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 26: First Test Run May Cause Injury Or Damage
If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 28: Enabling Device And Hold-To-Run Functionality
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 29: Risks Associated With Live Electric Parts
The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 30 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 31: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 32: Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 33: Safety Risks Related To Pneumatic/Hydraulic Systems
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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 34: Brake Testing
3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 35: Safety Risks During Handling Of Batteries
Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 36: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 37 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 38: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 39 Symbol Designation Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 40: Safety Symbols On Product Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 41 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 42 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 43 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 44 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 45 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
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Page 47: Installation And Commissioning
Safety on page 17 before performing any installation work. Note If the IRB 6620LX is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5...
Page 48: Robot Transportation Precautions
Transportation in any other way can seriously damage the robot. If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim. Method 1 - recommended method Transportation according to method 1 is strongly recommended by ABB.
Page 49: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 50 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 51 25 Hz. The robot should be mounted as rigid as possibly to the floor. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 52 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP 54 Manipulator, protection type Foundry Plus IP 67 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 53: Working Range And Type Of Motion
2 Installation and commissioning 2.3.2 Working range and type of motion 2.3.2 Working range and type of motion Type of Motion - IRB 6620LX-150/1.9 Axis Type of motion Range of movement IRB 6620LX-150/1.9 Travel length, Linear Axis 1.8 to 33 m Arm motion + 125°...
Page 54 2 Installation and commissioning 2.3.2 Working range and type of motion Continued xx0900000786 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 55: Risk Of Tipping/Stability
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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 56: On-Site Installation
Configurations Two configurations are used for the IRB6620LX. xx0900000226 Frame configuration for inverted mounting Frame configuration for side assembly Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 57 Section (12 m) Section (12 m) Sections at delivery 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)
Page 58 Upper leg sections with carriage track (lifting weight approx. 5,000 kg) (valid for 12 m) Upper leg sections with carriage track and carriage (lifting weight approx. 5,400 kg) (12 m) IRB 6620LX manipulator (lifting weight approx. 600 kg) Sections to assembly For assembly information see: •...
Page 59: Lifting And Securing The Frame
Securing the frame support on page 64 • Securing the frame support (welded) on page 65 At delivery the IRB 6620LX is divided into two sections. The sections and their weights are described in Frame configurations on page 56. The assembly of the IRB6620LX is therefore divided into sections.
Page 60 Continued Lifting the frame support xx0900000225 CAUTION The support frame weighs 1300 kg, all lifting equipment used must be sized accordingly. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 61 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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 62 Use lifting protective plates against sharp corners Assembling the frame supports xx0900000233 Nut M24 Screw M24 x 70 with washer Tightening torque: 725 Nm Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 63 Assemble the frame support to the frame using the Tightening torque 725 Nm sixteen M24 x 120 screws (use the distance plates). Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 64 Drill holes for the anchor bolts, use drills according to the table above. Assemble the anchor bolts according to the manufac- turer instructions. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 65 Use the ground levelling screw to adjust the height of each frame support. Use a water leveler to get the frame horizontal. When the support stands are positioned, weld the weld nuts according to the table above. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 66: Joining Two Frame Tracks
Track bar 2 Washer Distance plate Centering bolt Screws M20 x 105 Tightening torque: 600 Nm Action Note Move two sections together. xx0900000349 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 67 • D: Weld xx0900000355 Fix the frames using the two Tightening torque 600 Nm. centering bolts and the twelve attachment screws. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 68 Action Note Use a gauge (B) to adjust the gear racks (A). xx0900000362 Tighten the gear Tightening torque 83 Nm racks. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 69 Continued Action Note Measure the dis- tance X and Y: Desired value: X = Y ±0.02mm xx0900000346 • A: Guidance transition • B: Measurement tool Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 70: Lifting Robot With Fork Lift Accessory
The fork lift device accessory is fitted to the robot as shown in the figure. xx0900000168 Lifting and turning tool 3HAC034648-001 Fork lift pocket 2x screw M12x30 2x screw M12x20 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 71 348. 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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 72 If lifting with fewer than four fork lift pockets fitted, there is a risk of accidents happen! Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 73 2 Installation and commissioning 2.4.4 Lifting robot with fork lift accessory Continued Action Note CAUTION The IRB 6620LX robot weighs 610 All lifting accessories used must be sized accordingly! Carefully lift the robot and move it to its installation site. Note...
Page 74: Lifting The Robot With Lifting And Turning Tool
The lifting and turning tool 3HAC034648-001 is used for lifting and turning of the IRB 6620LX. xx0900000243 Upper lifting beam Lower lifting beam Locking screws Lifting eye Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 75 Attachment holes in the robot foot IRB 6620LX shipment pallet 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.
Page 76 2 Installation and commissioning 2.4.5 Lifting the robot with lifting and turning tool Continued Note Keep the shipment pallet for later storage of the IRB 6620LX. Action Note Use a fork lift to transport the IRB 6620LX to the CAUTION mounting site.
Page 77 Release the tension on the chain block until the robot is balanced. xx0900000250 Fit a lifting eye in the robot foot. xx0900000254 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 78 Lifting the robot with lifting and turning tool on page xx0900000244 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 79 Strap the cables to the base flange. xx0900000374 Remove: • A: Grease reservoir • B: Motor cover Fit: • C: Guide sleeves xx0900000267 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 80 R1.MP/R1.SMB onto the carriage. xx0900000245 Calibrate the robot. Described in the section Checking the synchronization position on page 335. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 81 Use a forklift for easier mounting of the lifting and turning tool. xx0900000244 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 82 A: Lifting beam lower • B: Screws 2x M12x20 • C: Screws 2x M12x30 Jog the robot into lifting position. xx0900000169 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 83 (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. xx0900000245 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 84 Dismantle procedure 90° Action Information Jog the robot axis to a position suitable for dis- mantling and mounting the turning tool. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 85 A: Lifting beam lower • B: Screws 2x M12x20 • C: Screws 2x M12x30 Jog the robot into lifting position. xx0900000382 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 86 This step is essential to prevent the overhead crane from damaging the carriage bearings. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 87 Remove the six (6) attach- ment screws. WARNING Personnel must not, un- der any circumstances, be present under the suspen- ded load! Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 88 Use the chain blocks to lower the robot until it is possible to use the forklift, or using a second chain block. xx0900000430 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 89 2.4.5 Lifting the robot with lifting and turning tool Continued Action Information Use the second chain block to lower the robot completely. xx0900000432 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 90 Lifting beam upper Lifting chains Turning the robot Action Information Attach the upper beam to the lower beam using the lifting chains. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 91 Use the chain block to lift and balance the robot. Remove the straps from the cables on the base flange. xx0900000374 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 92 Release the pressure on the chain block. xx0900000248 When the pressure is gone remove the chain block from the robot foot. Remove the lifting eye. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 93 2.4.5 Lifting the robot with lifting and turning tool Continued Action Information Fit a lifting eye in the robot upper arm. xx0900000250 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 94 Action Information Lift the robot using the chain block until the robot foot is horizontal. xx0900000251 Fit the robot onto the ship- ment pallet. xx0900000252 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 95: Manually Releasing The Brakes
Brake release at base The figure below shows the unit located at the base. xx0900000142 Internal brake release unit with push buttons Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 97 Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 98: Orienting And Securing The Robot
M24 x 100 Quality: Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 99 2 Installation and commissioning 2.4.7 Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. xx0900000172 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 100: Setting The System Parameters For A Suspended Or Tilted Robot
If the robot is mounted on a wall (rotated around the x-axis), then the robot base frame and the system parameter Gravity Alpha must be redefined. The value of Gravity Alpha should then be ±π/2 (±1.570796). Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 101 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. Position of the robot Gravity Alpha Gamma Rotation Suspended +3.141592...
Page 102: Fitting Equipment On Robot
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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 103 Illustration, fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm. xx0600002941 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 104 When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. Standard screws with quality 8.8 may be used when fitting other equipment to the mounting holes. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 105: Installing The Guide Trough
2.4.10 Installing the guide trough 2.4.10 Installing the guide trough Documentation For more information, see Transport and startup - E-chainsystems (IGUS) on myABB business portal (www.myportal.abb.com) or visit the homepage (www.gudel.com). Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 106: Lifting And Fitting The Cable Chain Igus
The complete cable chain weighs 8 - 15 kg / meter (depending on content). All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 107 With the chain lying on its side, secure the loose end to ensure that the chain can not unroll during the lift. xx1300000888 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 108 Refitting the energy chain on page 293. For more information, see Installation guide - Gliding applications (IGUS) on myABB business portal (www.myportal.abb.com) or visit the homepage (www.gudel.com). Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 109: Inspecting And Test Running The E-Chain Before Start-Up
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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 110: Loads Fitted To The Robot, 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. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 111: Optimizing The Performance
CAUTION If two IRB 6620LX are mounted on the same linear axis, then they may influence each other causing vibrations. Therefore, is the securing of the frame support extra important for applications where even small vibrations can cause disturbances.
Page 112 Adjusting TUNE_DF correctly will not affect the cycle time and path accuracy in any negative way. The ABB software TuneMaster is a good tool for finding the optimal value of TUNE_DF. TuneMaster is included in the RobotWare distribution.
Page 113: Signal Lamp (Option)
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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 114: Automatic Lubrication System
The flat rails and rack should be “wet” and have a thin oil film but not be soaked. If the lubrication is correctly adjusted a few floor drips may occur but not much more. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 115 System functions, mechanical connection, signal diagram, function description, maintenance, information about programming and setting up for operation is described in System manual - Automatic lubrication system (Güdel). Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 116: Electrical Connections
Robot cable signal, shielded: 15 m 3HAC7998-2 Robot cable signal, shielded: 22 m 3HAC7998-3 Robot cable signal, shielded: 30 m 3HAC7998-4 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 117 Continued Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 118: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 119: Maintenance
Safety on page 17 before performing any service work. Note If the IRB 6620LX is connected to power, always make sure that the IRB 6620LX is connected to protective earth before starting any maintenance work. For more information see: •...
Page 120: Maintenance Schedule And Expected Component Life
40000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.
Page 121: Maintenance Schedule
The following table specifies the required maintenance activities and intervals. Maintenance activity Equipment Interval Cleaning Robot Cleaning the IRB 6620LX on page 173 Inspection Oil level in axis-1 gearbox For more information, see the docu- mentation Operating manual - TM-O Sizes 40-90 (Güdel) or Operating manual - TM-O 1-4 (Güdel) on...
Page 122 Replacement Wiper and lubricating ele- Every 2.000 hours ment Replacement Lubricating pinion Every 2.000 hours Lubrication Ball bearings Every 2.000 hours Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 123 Rollers Every 2.000 hours For more information, see Operating manual - TM-O Sizes 40-90 (Güdel) or Operating manual - TM-O 1-4 (Güdel) on myABB business portal (www.myportal.abb.com) (depending on production year) or visit the homepage (www.gudel.com). Activities and intervals, e-chain The following table specifies the required maintenance activities and intervals.
Page 124: Expected Component Life
Examples of "extreme usage" in regard to movement: press tending, very severe palletizing applications, major use of axis 1 movement. iv The SIS for an IRC5 system is described in the Operating manual - Service Information System. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 125: Inspection Activities
For more information, see 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 production year) or visit the homepage (www.gudel.com). Product manual - IRB 6620LX 3HAC035737-001 Revision: P...
Page 126: Inspecting The Oil Level In Axis-2 Gearbox
143. Standard toolkit Content is defined in section Standard tools on page 348. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 127 143. Filling of oil is detailed further in the section Filling, oil on page 150. Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 128: Inspecting The Oil Level In Axis-3 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 129 Further information about how to fill the oil may be found in the section Filling, oil on page 154. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 130: Inspecting The Oil Level In Axis-4 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 131 Further information about how to fill the oil may be found in the section Filling, oil on page 156. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 132: Inspecting The Oil Level In Axis-5 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 133 Further information about how to fill the oil may be found in the section Filling, oil, axis 5 on page 159. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 134: Inspecting The Oil Level In Axis-6 Gearbox
Move axes 3 and 5 to a horizontal position, and make sure that the oil plug, filling and inspection is facing upwards. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 135 This will avoid surface tension from stopping air to enter into the gearbox. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 136 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 137: Inspecting The Information Labels
Instruction label concerning lifting Label for calibration Serial no. from rating label Required tools and equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 138 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare part lists on page 351. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 139: Inspecting The Axis-1 Mechanical Stop Pin
The axis-1 mechanical stop is located as shown in the figure. xx0900000176 Mechanical stop ax 1 Required equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 140 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. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 141: Inspecting, Signal Lamp
Use this procedure to inspect the function of the signal lamp. Action Note Check that signal lamp is lit when motors are put in operation ("MOTORS ON"). Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 142 Checking whether the signal lamp is broken. equipment on page 141. If so, replace it. • Checking cable connections. • Checking the cabling. Replace cabling if a fault is detected. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 143: Replacement/Changing Activities
Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
Page 144 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 145: Changing Oil, Axis-1 Gearbox
Axis 1 gearbox is located between the frame and base. Oil plugs are shown in the figure. xx0900000148 Vent screw Oil plug, filling Oil plug, draining Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 146 Use this procedure to drain oil in gearbox axis 1. xx0900000210 Gearbox axis 1 Attachment screws gearbox AC motor Attachment screws motor Flank Clutch locking screw Clutch Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 147 • air pressure supply to the robot, before entering the robot working area. Remove R2.MP1 and R2.FB1 connectors from the motor. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 148 Axis Calibration is described in Calibrating with Axis Calibration method on page 320. General calibration information is included in section Calibration on page 299. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 149: Changing Oil, Axis-2 Gearbox
Content is defined in section ment Special tools on page 349. Standard toolkit Content is defined in section Standard tools on page 348. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 150 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 151 126. page 143. Note Don´t mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 152: Changing Oil, Axis-3 Gearbox
143. Oil exchange equipment 3HAC021745-001 Content is defined in section Special tools on page 349. Oil collecting vessel Capacity: 3,000 ml. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 153 Draining is time-consuming. Elapsed time or grease) on page varies depending on the temperature of the oil. Refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 154 128. on page 143. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 155: Changing Oil, Axis-4 Gearbox
Special tools on page 349. Oil collecting vessel Capacity: 6,000 ml. Standard toolkit Content is defined in section Standard tools on page 348. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 156 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 157 130. amount is detailed in Type and amount of oil in gearboxes on page 143. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 158: Changing Oil, Axis-5 Gearbox
349. Oil collecting vessel Capacity: 4,000 ml. Standard toolkit Content is defined in sec- tion Standard tools on page 348. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 159 Before proceeding, please read the safety inform- ation in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 160 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 143. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 161: Changing Oil, Axis-6 Gearbox
Run the robot to a position where the oil plug, Shown in the figure Location of filling of axis 6 gearbox is facing downwards. gearbox on page 161. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 162 The correct oil level is detailed in section Inspect- amount of oil in gearboxes on ing the oil level in axis-6 gearbox on page 134. page 143. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 163 Refit the oil plug. Tightening torque: 24 Nm. Inspect the oil level. Detailed in the section Inspecting the oil level in axis-6 gearbox on page 134. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 164: Lubrication Of Ball Bearings And Surface Rollers
2,000 h. lubrication procedure Action Information Remove all 12 covers. Manually press the grease using a grease gun into each lubrica- tion nipple. Refit all 12 covers. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 165: Replacing The Smb Battery
See Operating manual - IRC5 with FlexPendant for instructions. WARNING See instructions for batteries, Safety risks during handling of batteries on page Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 166 Attachment screws SMB/BU unit (complete) Velcro strap Battery pack (2-pole battery contact) Battery pack (3-pole battery contact) Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 167 Equipment, etc. Spare part no. Note Battery pack For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part approved equivalent. lists on page 351 Standard toolkit Content is defined in section...
Page 168 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 166. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
Page 169 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 170: Replacement Of Felt Pinion
3.4.10 Replacement of felt pinion Location xx0900000277 Screws Distance piece Lubrication pinion O-ring Chamber Fixing bolts Washer Lubrication fitting Car plate Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 171 Remove the four screws holding the dis- (A) in figure. tance piece. Remove the chamber, o-ring and lubrica- (C, D, E) in figure. tion pinion. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 172: Replacing The Lubricant Cartridge And Battery
3.4.11 Replacing the lubricant cartridge and battery 3.4.11 Replacing the lubricant cartridge and battery Documentation For more information, see System manual - Automatic lubrication system (Güdel) on myABB business portal (www.myportal.abb.com) or visit the homepage (www.gudel.com). Product manual - IRB 6620LX 3HAC035737-001 Revision: P...
Page 173: Cleaning Activities
Turn off all electrical power supplies to 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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 174 R1.MP/R1.SMB General To secure high uptime it is important that the IRB 6620LX is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 6620LX.
Page 175 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
Page 176 3 Maintenance 3.5.1 Cleaning the IRB 6620LX Continued • Clean the cables if they have a crusty surface, for example from dry release agents. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 177: Repair
Make sure to read through the chapter Safety on page 17 before commencing any service work. Note If the IRB 6620LX is connected to power, always make sure that the IRB 6620LX is connected to earth before starting any repair work. For more information see: •...
Page 178: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 179: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 180 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. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 181: Mounting Instructions For Seals
Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 182 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 183: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 184: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 185: Complete Robot
Saving a reference using robot that is to be replaced Action Note Program a MoveAbsJ position and set all axes to Note If not possible, select another suitable position. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 186 Note Make sure not to change the position of the Cal- point laser pointer in relation to the turning disc. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 187 Tighten the attachment screws. xx0900000188 Run the preposition and the fine position. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 188 Action Note Validate if the laser point corresponds with the marked target. xx1700001007 Repeat the steps until the laser point corresponds to the marked target. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 189: Replacement Of Cable Harness, Lower End (Axes 1-2)
The figure shows the upper routing of the cable harness xx0900000161 Upper arm cable harness Metal clamp, lower arm (2 pieces) Cable bundle Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 190 The procedure below details how to remove the cable harness, axes 1-2. Action Note Decide which calibration routine to use, and take actions accord- ingly prior to beginning the re- pair procedure. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 191 Remove the metal clamps on Shown in the figure Location of cable harness, axes the frame, securing the cable 1-2 on page 189. harness. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 192 R1.MP and R1.SMB at the con- Shown in the figure Location of cable harness, axes nection plate, base. 1-2 on page 189. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 193 Axis Calibration is described in Calibrating with Axis Calibration method on page 320. General calibration information is included in section Calibration on page 299. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 194 These are fur- ther detailed in the section First test run may cause injury or damage on page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 195: Replacement Of Cable Harness, Upper End
Attachment screws, metal clamp lower arm, M6x16 quality 8.8 (2+2 pcs) Metal clamp, armhouse Attachment screws, metal clamp armhouse, M6x16 quality 8.8 (2 pcs) Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 196 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 197 Make sure not to lose the washers placed xx0600003024 in the holes of the foundry gasket. • A : Cover, wrist unit xx1400002580 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 198 A : Cable holder • B : Attachment screws M6x16, 8.8 (2 pcs) • C : Attachment screw M4x12, 8- A2F (securing the carrier) Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 199 Use caution and pull out the cable harness of the upper arm. Tie the connectors into a bundle, to avoid damaging them during further removal. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 200 Reconnect the motor cables axis 6 R2.MP6 Shown in the figure Location of cable and R2.FB6. harness on page 195 Refit cover motor, axis 6. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 201 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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 202 Make sure the wrist cover gasket and the small gasket fitted in the recess of the wrist cover are undamaged. Replace if damaged. xx1400002579 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 203 Fit the Foundry Plus cover on the adapter ring. xx1400002582 Make sure the gasket on the adapter ring is undamaged. Replace if damaged. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 204 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 205: Upper And Lower Arm
Location of turning disk The turning disk is located in the front of the wrist housing as shown in the figure below. The figure shows the turning disk on an IRB 6620 Foundry Plus/IRB 6620LX. xx0600003082 Turning disk Wrist unit...
Page 206 205. Remove the turning disk. Foundry Plus: Remove old flange sealant residues and other con- tamination from the contact surfaces. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 207 See section • Changing oil, axis-6 gearbox on page 161 Refit any equipment removed during disas- sembly to the turning disk. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 208 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 209: Replacement Of Wrist Unit
351. Wrist unit, insulated Spare part lists on page 351. Retrofit set Foundry Plus, Spare part lists wrist on page 351. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 210 Move the robot to a suitable position for removal of the wrist unit. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 211 Action Note Secure the wrist unit with a roundsling in an over- head crane and lift it to its mounting position. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 212 Axis Calibration is described in Calibrating with Axis Calibration method on page 320. General calibration information is included in section Calibration on page 299. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 213 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 214: Replacement Of The Upper Arm
Instruction 3HAC026600- 002 is enclosed. Lifting chain Roundsling Guiding pins Always use in pairs. Hoisting block Grease 3HAB3537-1 Used to lubricate o-rings. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 215 Lift away the robot from the track using the This is detailed in section Dismantle pro- lifting and turning tool 3HAC034648-001. cedure suspended on page Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 216 D : Hoisting block Remove the cable harness, axes 3-6. Detailed in the section Replacement of cable harness, upper end on page 195. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 217 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! Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 218 178. Refit the cable harness, axes 3-6. Detailed in section Replacement of cable harness, upper end on page 195. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 219 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 220: Replacement Of Lower Arm
See refer- quired. ences to these pro- cedures in the step- by-step instructions below. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 221 The procedure below details how to remove the lower arm. Action Note Decide which calibration routine to use, and take ac- tions accordingly prior to begin- ning the repair procedure. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 222 Secure the robot in upright position on the transportation plate. Secure the lower arm with a roundsling in an overhead crane. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 223 Refit the cable harness axes 3-6. Detailed in the section Replacement of cable harness, upper end on page 195. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 224 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 225: Frame And Base
Serial measurement unit (SMB), RMU 101 Brake release unit (BU), DSQC 1050 Push button guard Cover, push button guard Gasket (Foundry Plus) Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 226 Clean cover from metal residues before open- ing. Metal residues can cause shortage on the boards which can result in hazardous failures. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 227 A: Hexagon nut, M5 • B: Tooth lock washer, 6.4 fzb • C: Hexagon screw, M5x12 quality 8.8 Pull the SMB unit out carefully. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 228 Location of SMB the attachment screws. unit on page 225. Update the revolution counters! Detailed in section Updating revolution counters on page 314. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 229 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 230: Replacing The Brake Release Board
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 231 Location of the brake release unit is shown in the figure Location of brake release board on page 230. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 232 Refit the push button guard to the SMB cover. Shown in the figure Location of brake release board on page 230. Refit the cover, push button guard. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 233 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 234: Replacement Of Support Roller In Carriage
Safety risks during installation and service work on robots on page 23 Location of ball bearings xx0900000440 Tap screw Support roller Roller holder Cover Locking screw Flange Screw Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 235 Refit the flange using the four screws. Torque data for roller holder Roller holder size Torque data BR 40 BR 52 BR 62 BR 72 BR 90 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 236: Motors
FlexPendant. Location of motor The motor axis 1 is located as shown in the figure below. xx0900000216 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 237 Always download latest version from http://www.gudel.com. Operating manual - Toploader 546181387--001 Valid for elastomer coupling. (Güdel) Found on myABB business portal (www.myportal.abb.com). Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 238 Before entering the robot working area. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 239 For multi-tooth coupling, see Service manual - Gearbox unit HPG (Güdel). For elastomer coupling, see Operating manual - Toploader (Güdel). Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 240 Axis Calibration is described in Calibrating with Axis Calibration method on page 320. General calibration information is included in section Calibration on page 299. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 241: Replacement Of Motor Axis 2
Art. no. Note Motor including pin- Spare part lists on page 351. O-ring 21522012-430 Must be replaced when re- assembling motor! Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 242 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 243 The procedure below details how to remove the motor, axis 2. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair proced- ure. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 244 Location of motor on page 241. cable exit by unscrewing its two at- Make sure the gasket is not damaged! tachment screws. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 245 Make sure the motor pinion does not get dam- from the gear. aged! Remove the motor by gently pulling it onto the loading pallet. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 247 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 248: Replacement Of Motor, Axis 3
Used to rotate the motor pin- ion when mating it to the gear when brakes are released with 24 VDC power supply. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 249 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 250 Remove any equipment hindering access to motor axis 3. Remove the cover on top of the motor by unscrewing its four attach- ment screws. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 251 Remove the motor by gently lifting Make sure the motor pinion is not damaged! it straight out and disconnect the brake release voltage. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 252 In order to release the brake, connect the 24 VDC Connect to connector R2.MP3 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 253 Cal- ibrating with Axis Calibration meth- od on page 320. General calibration information is included in section Calibration on page 299. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 254 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 255: Replacement Of Motor, Axis 4
24 VDC, max. 1,5 A For releasing the brakes. Standard toolkit Content is defined in section Standard tools on page 348. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 256 The procedure below details how to remove the motor, axis 4. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 257 In order to release the brakes, connect the Connect to connector R2.MP4: 24 VDC power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 258 Axis Calibration is described in Calibrat- ing with Axis Calibration method on page 320. General calibration information is included in section Calibration on page 299. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 259 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 260: Replacement Of Motor, Axis 5 , Irb 6620/6620Lx
21522012-430 Must be replaced when reassembling motor! Grease 3HAB3537-1 For lubricating the o-ring. Loctite 574, Flange sealant 12340011-116 Option Foundry Plus Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 261 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 262 Fit the two guide pins in two of the motor attach- Art. no. is specified in Required ment screw holes. equipment on page 260. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 263 Detailed in the section Performing a leak-down test on page 178. Standard Refit the cover of the wrist unit with its attach- ment screws. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 264 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 265: Replacement Of Motor, Axis 6
Must be replaced when reas- sembling motor! Gasket 3HAC048560-001 Must be replaced when repla- cing motor Gasket, cover 3HAC033489-001 Must be replaced when opening cover. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 266 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 267 In order to release the brake, connect the 24 VDC Connect to connector R3.MP6 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 268 In order to release the brake, connect the 24 Connect to connector R3.MP6 VDC power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 269 Calib- rating with Axis Calibration method on page 320. General calibration information is in- cluded in section Calibration on page 299. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 270 • E: Gasket Continue to remove the motor unit, according to step 6 and forwards in Removal, motor on page 267. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 271 Apply Loctite 574 flange sealant on the contact surface. xx1400000992 Apply grease on the o-ring on the motor. Continue to refit the new motor according to section, Refitting, motor on page 268. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 272: Gearboxes
Gearbox with multi-tooth coupling xx0900000210 Gearbox axis 1 Attachment screws gearbox AC motor Attachment screws motor Flank Clutch locking screw Clutch Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 273 Always download latest version from http://www.gudel.com. Operating manual - Toploader 546181387--001 Valid for elastomer coupling. (Güdel) Found on myABB business portal (www.myportal.abb.com). Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 274 Replacement of motor, axis 1 on page 236. Recalibrate the robot. Described in the section Updating revolution coun- ters on page 314 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 275 - TM-O Sizes 40-90 (Güdel) or Operating manu- al - TM-O 1-4 (Güdel) (depending on production year). For elastomer coupling, see Operating manual - Top- loader (Güdel). Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 276: Replacement Gearbox Axis
3HAC020999-001 Used to turn the gear in correct position. Standard toolkit Content is defined in section Standard tools on page 348. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 277 The procedure below details how to remove gearbox axis 2. Action Note Decide which calibration routine to use, and take actions accord- ingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 278 Let the removed part of the cable harness hang loose and take care not to damage it during the remov- al process. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 279 Remove the gearbox and put it in a place where it will not/cannot be damaged. Wipe away residual oil and paint. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 280 The figure shows IRB6640. Fit two guide pins in two of the attachment holes, parallel to each other. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 281 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 282: Replacement Of Gearbox Axis 3
Instructions 3HAC 026600-002 is enclosed. Lifting tool 3HAC025214-001 For lifting gearbox. Standard toolkit Content is defined in section Standard tools on page 348. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 283 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 284 Fit two guide pins in two of the attachment holes, parallel to each other. Lift the gearbox on to the guide pins and push it to its mounting position. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 285 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 286: Replacement Of Gearbox, Axis 6
12 pcs, 13.1x1.6 Must be replaced when reas- sembling gearbox. Grease 3HAB3537-1 For lubricating the o-ring. Flange sealant 12340011-116 Loctite 574 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 287 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 288 A: M8 holes for pressing out the gearbox Foundry Plus: Remove old Loctite 574 flange sealant residues and other contamination from the contact sur- faces. xx1400001123 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 289 Detailed in the section Manually releasing the brakes on page Foundry Plus: Apply Loctite 574 flange sealant on the contact surface. xx1400001122 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 290 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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 291: Energy Chain
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 292 Loosen the fixed end of the energy chain. Screws: 4 pcs. xx1500000840 Loosen the drivers end of the energy chain. Screws: 4 pcs. xx1500000838 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 293 Refitting the energy chain For more information, see Installation guide - Gliding applications (IGUS) on myABB business portal (www.myportal.abb.com) or visit the homepage (www.gudel.com). Action Note Clean the energy chain and look for wear on the energy chain. Wear on the energy chain can cause damage to the cables.
Page 294 Perform a test run before powering up the Test run on page 295. linear axis to full speed and duty cycle. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 295 Check the tightening torque on fastening screws after 500 cycles. Adjust, if needed. Periodically check to see if the cable strain relief is still in place. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 296: Replacing Cables In The Energy Chain
4.8.2 Replacing cables in the energy chain Documentation For more information, see Installation guide - Gliding applications (IGUS) on myABB business portal (www.myportal.abb.com) or visit the homepage (www.gudel.com). Layout of cables inside the energy chain Cable layout, material handling - with hydraulic hose...
Page 297 Power 1 Power 2 Water To Water From Weld 2 Weld 3 Lubrication Weld 1 Signal SMB Profinet Power Earth Leoni Earth Güdel Profinet Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 298 This page is intentionally left blank...
Page 299: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 300: Calibration Methods
Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 6620LX and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
Page 301 Levelmeter calibration - alternative method Levelmeter calibration is referred to as the alternative method for calibration of ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.
Page 302: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors or parts of the transmission.
Page 303: Synchronization Marks And Axis Movement Directions
Synchronization mark, axis 6 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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 304: Calibration Movement Directions For All Axes
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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 305: Calibration And Configuration Of Joint Bound, Axis 1
5.3 Calibration and configuration of Joint Bound, axis 1 General This section describes how to fine calibrate axis 1 of IRB 6620LX. The calibration procedure differs depending on if the Axis Calibration method is available or not. This section describes both procedures.
Page 306 100 mm clearance between the dampers position. of the carriage and the end stop. xx1600001123 A Minimum clearance 100 mm (also other end of beam) Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 307 5.3 Calibration and configuration of Joint Bound, axis 1 Continued Action Note Locate the fixed calibration Wall mounted: pin on the carriage. xx1600001130 Suspended: xx1600001131 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 308 Drill the fastening threads for the Axis Calibration sup- port block screws (2 x M8) by using the drilling gauge. xx1600001133 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 309 (2 x Ø6 H7) using the Axis Calibration support block for guidance. xx1600001137 Insert the supplied dowel Dowel pins: 2 x Ø6 M6x20 pins. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 310 B Synchronization mark plate on the carriage, axis Fit the synchronization mark plate to the frame, using a drill for M5 screw hole dis- tance 60 mm. xx0900000388 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 311 This calibration method is only valid for axis 1. For all other axes the calibration methods described in section Calibration methods on page 300 must be used. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 312 Tapping Calibrate results in briefly displaying a dialog box, announcing that the calib- ration process has started. The axis is calibrated and the system returns to the list of available mechanical units. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 313 Use this procedure to configure the Joint Bound system parameters on the FlexPendant. Action Note Switch to manual mode. On the FlexPendant, tap the ABB menu and then tap Control Panel. Tap Configuration. This opens the system parameters configura- tion editor.
Page 314: Updating Revolution Counters
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 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 315 4 center. xx1500002404 If not: Jog the robot manually in the opposite direction to reach the correct position. xx1500002449 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 316 If one of the following mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 317 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 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 318 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 319 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 335. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 320: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 321 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 322 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. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 323: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 324 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 325: Installation Locations For The Calibration Tools
A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows. xx1600000004 xx1600000002 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 326 Replace damaged parts with new, if needed. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 327: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 328 Use this procedure to call for the Axis Calibration method on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 329 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 330 Confirm unsynchronized state by pressing Ac- knowledge to continue Axis Calibration proced- ure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 331 SafeMove generates the message "Unsynchron- ized time limit expired" (anytime). xx1500002482 Press OK to continue Axis Calibration procedure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 332 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC056806-001. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 333: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 334: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Remove any calibration equipment from the robot. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 335: Checking The Synchronization Position
If they do not, up- ization position for axes on page 303 date the revolution counters. Updating revolution counters on page 314. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
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Page 337: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 338 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 339: Scrapping Of Robot
• 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 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
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Page 341: Reference Information
European standards Standard Description EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 342 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 343: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 344: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 345 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 346 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 347: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 348: Standard Tools
To be shortened to 12 mm Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 349: Special Tools
Calibration tool box, Axis Cal- 3HAC055412- Delivered as a set of calibration tools. ibration Required if Axis Calibration is the valid calibration method for the robot. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 350: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 351: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
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Page 353: Circuit Diagram
Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 354 9 Circuit diagram 9.1 Circuit diagrams Continued Product Article numbers for circuit diagrams Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001...
Page 355: Index
116 axis-4, 130 connection axis-3, 128 external safety devices, 24 axis-2, 126 copper installing equipment on robot, 102 disposal, 337 instructions for assembly, 47 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 356 303 protective equipment, 24 screw joints, 344 protective wear, 24 securing the robot to foundation, attachment screws, 98 signal lamp, 113 signals Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 357 223 Gravity Alpha, 101 motor, 239–240, 251–252 robot, 73, 347 upper arm, 216–217 temperatures operation, 52 storage, 52 zero position testing checking, 335 brakes, 34 Product manual - IRB 6620LX 3HAC035737-001 Revision: P © Copyright 2009-2018 ABB. All rights reserved.
Page 360 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2009-2018 ABB. All rights reserved. Specifications subject to change without notice.

ABB IRB 6620LX Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Part Lists

9 Circuit Diagram

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