ABB IRB 6600 - 175/2.55 User Manual

Industrial robot

page of 1020

/ 1020
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Product Manual

Industrial Robot

IRB 6600 - 225/2.55

IRB 6600 - 175/2.8

IRB 6600 - 175/2.55

IRB 6650 - 200/2.75

IRB 6650 - 125/3.2

M2000A

Table of Contents

Summary of Contents for ABB IRB 6600 - 175/2.55

Page 1 Product Manual Industrial Robot IRB 6600 - 225/2.55 IRB 6600 - 175/2.8 IRB 6600 - 175/2.55 IRB 6650 - 200/2.75 IRB 6650 - 125/3.2 M2000A...
Page 3 Product Specification 3HAC 14064-1/M2000/Rev 2 IRB 6600 - 175/2.55 IRB 6600 - 225/2.55 IRB 6600 - 175/2.8 IRB 6650 - 125/3.2 IRB 6650 - 200/2.75...
Page 4 Products AB, Robotics assumes no responsibility for any errors that may appear in this document. In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.
Page 5 Product Specification IRB 6600 CONTENTS Page 1 Description ........................3 1.1 Structure........................3 Different robot versions ..................4 Definition of version designation................4 1.2 Safety/Standards ..................... 6 1.3 Installation ......................10 External Mains Transformer .................. 10 Operating requirements..................10 Mounting the manipulator..................10 1.4 Load diagrams ......................
Page 6 Product Specification IRB 6600 Product Specification IRB 6600 M2000...
Page 7 Description 1 Description 1.1 Structure A new world of possibilities opens up with ABB’s IRB 6600 robot family. It comes in five versions, 175kg /2.55m, 225kg /2.55 m, 175kg /2.8m, 125kg/3.2m, and 200kg/2.75m handling capacities. The IRB 6600 is ideal for process applications, regardless of industry. Typical areas can be spotwelding, material handling and machine tending.
Page 8 Description Different robot versions The IRB 6600 is available in five versions. The following different robot types are available: Standard: IRB 6600 - 175 kg / 2.55 m IRB 6600 - 225 kg / 2.55 m IRB 6600 - 175 kg / 2.8 m IRB 6650 - 125 kg / 3.2 m IRB 6650 - 200 kg / 2.75 m Definition of version designation...
Page 9 Description ; IRB 6650-2.75 1142 IRB 6600-2,55 1392 IRB 6600-2,8 1592 IRB 6650-3.2 6600-400/2.55 R 580 R 690 with fork lift Figure 2 View of the manipulator from the side and above (dimensions in mm). Allow 200 mm behind the manipulator foot for cables. Product Specification IRB 6600 M2000...
Page 10 Description 1.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218, EN 775...
Page 11 Description The ABS is active during all stop modes, braking the robot to a stop with the power of the servo drive system along the programmed path. After a specific time the mechanical brakes are activated ensuring a safe stop even in case of a failure of the drive system or a power interruption.
Page 12 Description The lower arm is shaped inward, giving more space under the upper arm to re-orientate large parts and leaving more working space while reaching over equipment in front of the robot. The rear side of the upper arm is compact, with no components projecting over the edge of the robot base even when the robot is moved into the home position.
Page 13 Description Delayed safeguarded space stop A delayed stop gives a smooth stop. The robot stops in the same way as at a normal program stop with no deviation from the programmed path. After approx. 1 second the power supplied to the motors is shut off. Hold-to-run control “Hold-to-run”...
Page 14 Description 1.3 Installation All versions of IRB 6600 are designed for floor mounting. Depending on the robot version, an end effector with max. weight of 175 to 225 kg including payload, can be mounted on the mounting flange (axis 6). See Load diagram for IRB 6600 generation robots on page 14, page 16, page 18, page 20 and page 22.
Page 15 Description Recommended screws for fastening the manipulator to a base plate: M24 x 120 8.8 with 4 mm flat washer Torque value 775 Nm Figure 3 Hole configuration (dimensions in mm). Product Specification IRB 6600 M2000...
Page 16 Description A - A B - B C - C Two guiding pins required, dimensions see Figure 5 Figure 4 Option Base plate (dimensions in mm). Product Specification IRB 6600 M2000...
Page 17 For an accurate load diagram, please use the calculation program, ABBLoad for 6600 on: • inside.abb.com/atrm, click on Products --> Robots --> IRB 6600 • http://www.abb.com/roboticspartner, click on Product range --> Robots --> IRB 6600. Centre of gravity 50 kg Figure 6 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).
Page 18 Description Load diagram for IRB 6600-175/2.55 0,80 80 kg 0,70 100 kg 0,60 120 kg 0,50 135 kg 150 kg 0,40 175 kg 0,30 180 kg 185 kg 0,20 0,10 0,00 0,10 0,00 0,10 0,20 0,30 0,40 0,50 L-distance (m ) Figure 7 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity).
Page 19 Description Load diagram for IRB 6600-175/2.55 “Vertical Wrist” (±10 “Vertical wrist” load Load diagram "Vertical Wrist" (±10°) IRB 6600 - 175/2.55 Armload: 50kg L-distance (m) 0,20 0,40 0,60 0,80 1,00 1,20 1,40 0,20 210 kg 190 kg 0,40 150 kg...
Page 20 Description Load diagram for IRB 6600-225/2.55 0,90 100 kg 0,80 0,70 120 kg 0,60 150 kg 0,50 175 kg 200 kg 0,40 215 kg 220 kg 0,30 225 kg 230 kg 0,20 0,10 0,00 0,00 0,10 0,10 0,20 0,20 0,30 0,40 0,50 0,60...
Page 21 Description Load diagram for IRB 6600-225/2.55 “Vertical Wrist” (±10 “Vertical wrist” load Load diagram "Vertical Wrist" (±10°) IRB 6600 - 225/2.55 Armload: 50kg L-distance (m) 0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40 0,00 0,20 260 kg 235 kg 0,40 200 kg 0,60 150 kg...
Page 22 Description Load diagram for IRB 6600-175/2.8 1,10 1,00 80 kg 0,90 100 kg 0,80 0,70 120 kg 0,60 150 kg 0,50 170 kg 0,40 175 kg 180 kg 0,30 185 kg 0,20 0,10 0,00 0,20 0,00 0,10 0,10 0,20 0,30 0,40 0,50 0,60...
Page 23 Description Load diagram for IRB 6600-175/2.8 “Vertical Wrist” (±10 “Vertical wrist” load L-distance (m ) 0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40 0,00 0,20 210 kg 190 kg 0,40 170 kg 125 kg 0,60 100 kg 0,80 1,00 1,20 Figure 12 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity) at “Vertical Wrist”...
Page 24 Description Load diagram for IRB 6650-125/3.2 1,10 1,00 80 kg 0,90 90 kg 0,80 100 kg 0,70 110 kg 0,60 115 kg 0,50 120 kg 0,40 125 kg 0,30 130 kg 0,20 0,10 0,00 0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,20...
Page 25 Description Load diagram for IRB 6650-125/3.2 “Vertical Wrist” (±10 “Vertical wrist” load Load diagram "Vertical Wrist" (±10°) IRB 6650 - 125/3.20 Armload: 50kg L-distance (m) 0,20 0,40 0,60 0,80 1,00 1,20 1,40 1,60 150 kg 0,20 135 kg 0,40 120 kg 110 kg 0,60 100 kg...
Page 26 Description Load diagram for IRB 6650-200/2.75 0,90 0,80 100 kg 0,70 120 kg 135 kg 0,60 150 kg 0,50 175 kg 195 kg 0,40 200 kg 0,30 205 kg 210 kg 0,20 0,10 0,00 0,10 0,00 0,10 0,20 0,30 0,40 0,50 0,60 L-distance (m)
Page 27 Description Load diagram for IRB 6650-200/2.75 “Vertical Wrist” (±10 “Vertical wrist” load Load diagram "Vertical Wrist" (±10°) IRB 6650 - 200/2.75 Armload: 50kg L-distance (m) 0,20 0,40 0,60 0,80 1,00 1,20 1,40 235 kg 0,20 210 kg 0,40 175 kg 0,60 125 kg 0,80...
Page 28 Description Maximum load and moment of inertia for full and limited axis 5 (centre line down) movement. Note. Load in kg, Z and L in m and J in kgm Full movement of axis 5 (±120 Axis 5 Maximum moment of inertia: ≤...
Page 29 Description Mounting equipment Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame. Definitions of distances and masses are shown in Figure 19 and Figure 20. The robot is supplied with holes for mounting extra equipment (see Figure 21). Maximum permitted arm load depends on centre of gravity of arm load and robot payload.
Page 30 Description Mounting of hip load The extra load can be mounted on the frame. Holes for mounting see Figure 21 and ∅ Figure 22. When mounting on the frame all the four holes (2x2, 16) on one side must be used. Holes for mounting extra equipment Figure 21 Holes for mounting extra equipment on the upper and the lower arm, and the frame (dimensions in mm).
Page 31 Description Figure 22 Holes for mounting of extra load on the upper arm (dimensions in mm). Product Specification IRB 6600 M2000...
Page 32 Description IRB 6600-175/2.55 0,04 A 12 H7 Depth 15 0,02 CD 100 H7 Depth 8 min 0,02 A B - B M12 ( 11x ) 0,2 A B Figure 23 Robot tool flange (dimensions in mm). Product Specification IRB 6600 M2000...
Page 33 Description IRB 6600-225/2.55 IRB 6600-175/2.8 IRB 6650-125/3.2 0,04 A IRB 6650-125/3.2 12 H7 Depth 15 0,02 C D 100 H7 Depth 8 min M12 ( 11x ) 0,02 A 0,2 A B Figure 24 Robot tool flange (dimensions in mm). Product Specification IRB 6600 M2000...
Page 34 Description 1.5 Maintenance and Troubleshooting The robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible: - Maintenance-free AC motors are used. - Oil is used for the gear boxes. - The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change.
Page 35 Description 1.6 Robot Motion Type of motion Range of movement Axis 1 Rotation motion +180 to -180 Axis 2 Arm motion Axis 3 Arm motion to -180 Axis 4 Wrist motion +300 to -300 Axis 5 Bend motion +120 to -120 Axis 6 Turn motion +300 to -300...
Page 36 Description IRB 6600-175/2.8 Figure 26 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm). Product Specification IRB 6600 M2000...
Page 37 Description IRB 6650-125/3.2 Figure 27 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm). IRB 6650-200/2.75 Figure 28 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm). Product Specification IRB 6600 M2000...
Page 38 Description Performance according to ISO 9283 At rated maximum load, maximum offset and 1.6 m/s velocity (for IRB 6600-225/2.55, 1.0 m/s velocity) on the inclined ISO test plane, 1 m cube with all six axes in motion. Data for IRB 6650 not yet available. IRB 6600 -175/2.55 -225/2.55...
Page 39 Description 1.8 SpotPack and DressPack The different robot types can be equipped with the option SpotPack for IRB6600/6650. The SpotPack IRB6600/6650 is designed for spot welding and handling applications. The function package supplies the transformer gun or the robot gripper with necessary media, such as compressed air, cooling water and electrical power.
Page 40 Description The SpotPack for IRB6600/6650 is modular based and contains the main modules shown in the schematic picture below. Option description specifies different module combinations. Robot gun/gripper Upper arm harness Lower arm harness Power unit Water and air unit Control Cabinet Pedestal Floor...
Page 41 Description Description of DressPack The DressPack contains the maximum wire and media capacity as described below. The number of signals that are available in each case depends on the choice of different option combinations (see option description). The interface connectors for the signals are also specified under each option description.
Page 42 Description Spot Welding application The cables and hoses used for the DressPack for the Spot Welding application has the following specification and capacity: Table 3 Type Area Allowed capacity Customer Power (CP) Servo motor power 1,5 mm 600 VAC, 12 A rms Utility Power 0,5 mm 500 VAC, 5 A rms...
Page 43 Description Description of Water and Air unit The Water and Air unit contains components for water and air distribution and control within the SpotPack. The water and air unit is via the process software controlled from the robot controller. Wiring is made via the power unit. The capacity and functionality depends on the choice of different option combinations, see option description.
Page 44 Description Description of Power Unit The Power unit contains components for power distribution and control within the SpotPack. The power unit with the welding controller built in, is controlled from the robot controller via the process software.. Wiring is made between robot controller (I/O-board and internal cabling in the DressPack) and the power unit.
Page 45 Description 1.9 Description of Variants and Options for SpotPack The following specification describes all main parts with main data for the SpotPack and Dresspack IRB 6600/6650. Required options for SpotPack IRB 6600/6650 different types To enable the spot welding function package SpotPack IRB 6600/6650 to perform as intended, general standard robot options for the three different types are required.
Page 46 Description SpotPack Type HS with servo requires the following additional options: Option 381 Drive unit type DDU-U Option 702 Stationary Gun. Option 686-689 Connection of servo gun (7 - 30 m) Option 625 SpotWare Servo (software option for servo guns) replaces option 553).
Page 47 Description 1.9.2 DressPack options Dress Pack options includes options for Upper arm harness, Lower arm harness and Floor harness. These are described separated below but are designed and meant to be seen as a complete package for either Material handling or Spot welding application. The Upper Arm Harness consists of a process cable package and supports, clamps, brackets and a retractor arm.
Page 48 Description The lower arm harness is connected to the upper arm harness at the connection point under the axis 3 motor. The interface plate at the manipulator base is the place where the floor harness and the process media are connected. The Floor Harness consists of signal cables for customer signals.
Page 49 Description Communication Option 2063 Parallel communication The process cable package has been chosen for parallel communication. The number as well as the type of signals are defined under Material handling application (Option 2204,2205) and Spot welding application (Option 2200). Option 2064 Bus communication The process cable package has been chosen for bus communication.
Page 50 Description Table for Material Handling with option 2063 with or without Servo gun option Table 7 Type Pcs at Pcs at Connection Allowed capacity Terminal* point** Customer Power (CP) Utility Power 500 VAC, 5 A rms Protective earth 500 VAC Customer Signals (CS) Signals twisted pair 50 VAC, 1 A rms...
Page 51 Description Table for Material Handling with option 2064 and Interbus Table 9 Type Pcs at Pcs at Connection Allowed capacity Terminal* point** Customer Power (CP) Utility Power 500 VAC, 5 A rms 500 VAC Protective earth Customer Bus (CBus) Bus signals Interbus spec Bus signals 50 VAC, 1 A rms...
Page 52 Description Option 2200 Spot Welding to axis 3, and option 2201 Spot Welding to axis 6 The Lower arm harness and the Upper arm harness for Spot Welding has been chosen. This includes the process cable package as well as brackets, connectors etc to form a complete dressing package from manipulator base to the connectors on axis 6.
Page 53 Description Table for Spot Welding with option 2063 Table 12 Type Pcs at Pcs at Connection Allowed capacity Terminal* point** Customer Power (CP) Utility Power 500 VAC, 5 A rms Protective earth 500 VAC Customer Signals (CS) Signals twisted pair 50 VAC, 1 A rms Signals twisted pair and 50 VAC, 1 A rms...
Page 54 Description Table for Spot Welding with option 2064 and CAN/DeviceNet Table 14 Type Pcs at Pcs at Connection Allowed capacity Terminal* point** Customer Power (CP) Utility Power 500 VAC, 5 A rms Protective earth 500 VAC Customer Bus (CBus) Bus signals CAN/DeviceNet spec Bus signals 50 VAC, 1 A rms...
Page 55 Description Table for Spot Welding with option 2064 and Profibus Table 16 Type Pcs at Pcs at Connection Allowed capacity Terminal* point** Customer Power (CP) Utility Power 500 VAC, 5 A rms 500 VAC Protective earth Customer Bus (CBus) Bus signals Profibus 12Mbit/s spec Bus signals 50 VAC, 1 A rms...
Page 56 The basic power unit for type S is equipped for a robot handled AC Spotwelding gun and with the following components: - Cable gland for incoming power (X100) - Circuit Breaker type ABB SACE, T1 160 A - Welding Timer and Thyristor type Bosch PST 6100.100L 76kVA - Fuse terminal for 24 V distribution - Connector to Water and air unit, Modular Harting.
Page 57 The basic power unit for type HS is equipped for a stationary / pedestal mounted AC Spotwelding gun and with the following components: - Cable gland for incoming power (X100) - Circuit Breaker type ABB SACE, T1160 A - Welding Timer and Thyristor type Bosch PST 6100.100L76kVA - Fuse terminal for 24 V distribution - Connector to Water and air unit, Modular Harting.
Page 58 Description Option 2096 Weld power cable, 15 m This option includes floor cable of 15 m length for weld power. See description for option 2095. Option 2117 Process cable to stationary gun, 7m This option includes floor cable of 7 m length for process signals to the pedestal/ stationary gun.
Page 59 Description Water return circuit The water return circuit monitors the flow of the returning cooling water from the Spot welding gun. The flow switch detects if the water flow is too low in the cooling water circuit. The flow switch gives a digital signal to the robot control system, which automatically shuts the electrical shut off valve in the water in circuit off if the flow is too low.
Page 60 Description The cable and cable length between the Split box and the Power unit has to be specified (see option 2183, 2184 and 2185). El. shut off XS 101.1 XS 101.2 Flow switch 1 Option Flow switch 2 XS 101.3 Option Air pressure switch XS 101.4...
Page 61 Description Hoses between water in circuit and water return circuit are not supplied. These have to be arranged by the customer. Option 2177 Second water return When the water pressure drop is to high because of too long hoses or because of any other reason, an additional water return circuit can be the best solution to solve this problem.
Page 62 Description Option 2181 Electrical proportional valve for air The option includes a proportional valve with integrated control circuit and connection cable to the splitbox. The proportional valve controls the pinching force of the pneumatic spot welding gun and is designed to obtain optimal performance during long operation time.
Page 63 Description 1.10 Examples of SpotPacks To support the understanding of how the different options could be combined to complete SpotPacks some examples are shown below. Note that these are examples of possible configurations and that each case has to be analysed based on the unique production conditions.
Page 64 Description 2087 Power unit, AC welding type S AC welding with robot handled gun 2095 Weld power cable / 7m. Specifies power cable for welding 2174 Water and air unit / Type S 2181 Electrical proportional valve for air Programmable pressure for pneumatic gun 2183 Cable to split box / 7m Specifies floor cable length to split box...
Page 65 Description 2174 Water and air unit / Type S. 2183 Cable to split box / 7m Specifies floor cable length to split box Example 4: SpotPack for SpotWelding with pedestal servo gun and Interbus interface to robot handled gripper. Option no Name / Note General options No upper cover on robot control cabinet...
Page 66 Description 1.11 Servo Gun (option) The robot can be supplied with hardware and software for Stationary Gun, Robot Gun, Stationary and Robot Gun, Twin Staionary Guns, Stationary Gun and Track Motion or Robot Gun and Track Motion. For configuration and specification of hardware and software respectively, see each section below.
Page 67 Description 1.11.2 Robot Gun (RG) option 702 option 381 option 702 DDU-V options 2063 options 697-699 (options 641-644) Figure 33 Configuration of Robot Gun. Options according to Table 18 below are required to complete the delivery. For further details see corresponding Product Specification. Table 18 Option Description...
Page 68 Description 1.11.3 Stationary and Robot Gun (SG + RG) options 697-699 option 382 options 2063 option 703 DDU-VW M7C1B1.CFG (options 641-644) options 686-689 Figure 34 Configuration of Stationary and Robot Gun. Options according to Table 19 below are required to complete the delivery. For further details see corresponding Product Specification.
Page 69 Description 1.11.4 Twin Stationary Guns (SG + SG) option 382 DDU-VW (options 641-644) M7C1B1.CFG SG 1 options 686-689 SG 2 option 704 Figure 35 Configuration of Twin Stationary Guns. Options according to Table 20 below are required to complete the delivery. For further details see corresponding Product Specification.
Page 70 Description 1.11.5 Stationary Gun and Track Motion (SG + TM) option 382 DDU-VW (options 641-644) M7C1B1.CFG options 686-689 option 705 Figure 36 Configuration of Stationary Gun and Track Motion. Options according to Table 21 below are required to complete the delivery. For further details see corresponding Product Specification.
Page 71 Description 1.11.6 Robot Gun and Track Motion (RG + TM) option 382 option 706 options 2063 DDU-VW M7C1B1.CFG (options 641-644) options 697-699 Figure 37 Configuration of Robot Gun and Track Motion. Options according to Table 22 below are required to complete the delivery. For further details see corresponding Product Specification.
Page 72 Description 1.12 Track Motion The robot can be supplied with a Track Motion, see Product Specification IRBT 6003S. For configuration and specification of hardware see Figure 38. option 383 option 2204 or 2200 DDU-W or 383 M7C1B1.CFG TM delivery (options 641-644) Figure 38 Configuration of Track Motion.
Page 73 023 IRB 6600-225/2.55 024 IRB 6600-175/2.55 025 IRB 6650-125/3.2 027 IRB 6650-200/2.75 Manipulator colour 330 Standard The manipulator is painted in ABB orange. 352 RAL code Colours according to RAL-codes. Protection 035 Standard (IP 67) 036 Foundry Robot adapted for foundry or other harsh environments.
Page 74 Specification of Variants and Options 2200 Spot Welding from base to axis 3 Requires Communication Parallel or Bus option 2063/2064. See Figure 40, and Description of DressPack on page 37, Table 3, Table 11, Table 12, Table 13, Table 14, Table 15 and Table 16. 2201 Spot Welding from axis 3 to axis 6 Requires Spot Welding from base to axis 3, option 2200, and communication Parallel or Bus, options 2063/2064.
Page 75 Specification of Variants and Options R1.SW1 R3.FB7 R1.MP R1.SMB R1.SW2/3 R1.PROC1 1 x 1/2” R1.CP/CS Figure 41 Location of MH connections on the foot. R2.CP/CS R2.MP 5/6 R2.PROC1 1 x 1/2” Figure 42 Location of MH connections on axis 3. R1.CP/CS R1.WELD 3 x 35mm R1.MP...
Page 76 Specification of Variants and Options Connection to 056 Manipulator The signals are connected directly to the manipulator base to one heavy duty industrial housing with a Harting modular connector R1.CP/CS see Figure 41 and Figure 43). The cables from the manipulator base are not supplied. 057 Cabinet The signals CP/CS are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, in the controller.
Page 77 Specification of Variants and Options 114 Cooling fan for axis 2 motor (IP 54) For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115). Not for protection Foundry. 115 Cooling fan for axis 3 motor (IP 54) For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115).
Page 78 Specification of Variants and Options 089 Insulated tool flange The electrically insulated tool flange, according to European Standard EN 60204-1, withstands dangerous voltage (in case of an electrical fault in the spot welding equipment mounted on the Insulated tool flange) of 500V DC during 30 seconds in non water applications without passing it further to the electronics in the manipulator and the controller.
Page 79 Specification of Variants and Options 2223 R3.FB7 For the 7-axis connector on the manipulator base. 2224 R2.CP/CS and PROC1 For the Customer Power/Customer Signal connector and one Process connector at axis 3. Pins for bus communication are included. 2225 R2.WELD and PROC2-4 For the Weld connector and three Process connectors at axis 3.
Page 80 Specification of Variants and Options Connection of switches axis 1 (cable lengths) 078 7m 079 15m 081 30m 072 Position switches axis 2 Two redundant position zones are available, each with two independent switches and cams. 073 Position switches axis 3 Two redundant position zones are available, each with two independent switches and cams.
Page 81 Specification of Variants and Options Weld power cable 2095 7m 2096 15m Process cable to Stationary Gun 2117 7m 2118 15m 2119 30m Water and Air Fore more information see chapter 1.9.4 Water and Air Unit 2174 Water and Air unit type S 2175 Water and Air unit type HS 2177 Second water return 2192 Digital flow meter, one water return...
Page 82 Specification of Variants and Options Product Specification IRB 6600 M2000...
Page 83 R1.BU on the manipulator frame. The brake release box can be ordered from ABB Automation Technology Products, Robotics, department S. Calibration Cube This calibration tool can be ordered from ABB Automation Technology Products, Robotics, department S. Product Specification IRB 6600 M2000...
Page 84 Accessories Product Specification IRB 6600 M2000...
Page 85 Index 4 Index motion 31 mounting extra equipment 25 robot 10 accessories 79 mounting flange 28, 29 Active Brake System 6 noise level 4 Collision detection 7 colours 69 cooling device 4 operating requirements 10 options 69 overspeed protection 7 Electronically Stabilised Path 7 emergency stop 8 enabling device 8...
Page 86 Index temperature 10 troubleshooting 30 Twin Stationary Guns 65 variants 69 weight 4 working space restricting 7, 10, 76 zone switches 8 Product Specification IRB 6600 M2000...
Page 87 Big Inertia ......................21 Soft Servo....................... 21 1.12 External Axes ....................... 21 1.13 I/O System ......................23 Types of connection ....................24 ABB I/O units (node types) ................... 24 Distributed I/O ....................... 25 Signal data......................26 Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 88 Product Specification S4Cplus System signals......................27 1.14 Communication ....................29 2 Specification of Variants and Options................31 3 Index..........................51 Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 89 Description 1 Description 1.1 Structure The controller contains the electronics required to control the manipulator, external axes and peripheral equipment. The controller also contains the system software, i.e. the BaseWare OS (operating system), which includes all basic functions for operation and programming. Controller weight 250 kg Controller volume:...
Page 90 Description Air distance to wall Cabinet extension Option 124 Extended cover Option 123 980 * Lifting points for forklift * Castor wheels, Option 126 Figure 2 View of the controller from the front, from above and from the side (dimensions in mm). Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 91 Description 1.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218, EN 775...
Page 92 Description Safe manual movement The robot is moved using a joystick instead of the operator having to look at the teach pendant to find the right key. Over-speed protection The speed of the robot is monitored by two independent computers. Emergency stop There is one emergency stop push button on the controller and another on the teach pendant.
Page 93 Description 1.3 Operation All operations and programming can be carried out using the portable teach pendant (see Figure 3) and operator’s panel (see Figure 5). Hold-to-run Menu keys Motion keys Display Window keys Joystick Enabling device Emergency stop button Function keys Navigation keys Cable 10 m Figure 3 The teach pendant is equipped with a large display, which displays prompts,...
Page 94 Description - File management - System configuration - Service and troubleshooting - Automatic operation User-defined keys (P1-P5) Five user-defined keys that can be configured to set or reset an output (e.g. open/close gripper) or to activate a system input. Hold-to-run A push button which must be pressed when running the program in manual mode with full speed.
Page 95 Description - Programming - System setup - Service and installation Operator’s panel MOTORS ON button Operating mode selector and indicating lamp Emergency stop Duty time counter If pressed in, Indicates the operating time for pull to release the manipulator (released brakes) MOTORS ON Continuous light Ready for program execution...
Page 96 Description Both the operator’s panel and the teach pendant can be mounted externally, i.e. separated from the cabinet. The robot can then be controlled from there. The robot can be remotely controlled from a computer, PLC or from a customer’s panel, using serial communication or digital system signals.
Page 97 Description 1.4 Memory Available memory The controller has two different memories: - a fixed DRAM memory of size 32 MB, used as working memory - a flash disk memory, standard 64 MB, used as mass memory. Optional 128 MB. The DRAM memory is used for running the system software and the user programs and it is thus divided into three areas: - system software - system software execution data...
Page 98 Description Several different systems, i.e. process applications, may be installed at the same time in the controller, of which one can be active. Each such application will occupy another 10 MB of the flash memory for system data. The release storage area will be in common as long as the process applications are based on the same release.
Page 99 Description Rated power: IRB 140, 1400, 2400 4.5 kVA (transformer size) IRB 340, 1400 , 2400 ,4400, 6400, 940 7.8 kVA (transformer size) IRB 6600 6 kVA IRB 7600 7.1 kVA External axes cabinet 7.2 kVA (transformer size) Computer system backup capacity 20 sec (rechargeable battery) at power interrupt Configuration...
Page 100 Description The programming environment can be easily customized using the teach pendant. - Shop floor language can be used to name programs, signals, counters, etc. - New instructions can be easily written. - The most common instructions can be collected in easy-to-use pick lists. - Positions, registers, tool data, or other data, can be created.
Page 101 Description a standard PC. Editing programs Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy, delete, find and change, undo etc. Individual arguments in an instruction can also be edited using these commands. No reprogramming is necessary when processing left-hand and right-hand parts, since the program can be mirrored in any plane.
Page 102 Description Select program to run: Front A Front B Front C Other Service Figure 8 The operator dialogs can be easily customised. A special input can be set to order the robot to go to a service position. After service, the robot is ordered to return to the programmed path and continue program execution.
Page 103 Description 1.9 Exception handling Many advanced features are available to make fast error recovery possible. Characteristic is that the error recovery features are easy to adapt to a specific installation in order to minimise down time. Examples: - Error Handlers (automatic recovery often possible without stopping production).
Page 104 Description 1.11 Robot Motion Motion concepts QuickMove The QuickMove concept means that a self-optimizing motion control is used. The robot automatically optimizes the servo parameters to achieve the best possible performance throughout the cycle - based on load properties, location in working area, velocity and direction of movement.
Page 105 Description Tool Centre Point (TCP) Tool coordinates Base coordinates Axis 3 Axis 2 Axis 3 Base coordinates Axis 1 Axis 1 Tool coordinates Tool Centre Point (TCP) Object coordinates User coordinates World coordinates Figure 9 The coordinate systems, used to make jogging and off-line programming easier. The world coordinate system defines a reference to the floor, which is the starting point for the other coordinate systems.
Page 106 Description Stationary TCP When the robot is holding a work object and working on a stationary tool, it is possible to define a TCP for that tool. When that tool is active, the programmed path and speed are related to the work object. Program execution The robot can move in any of the following ways: - Joint motion (all axes move individually and reach...
Page 107 Description External axes Very flexible possibilities to configure external axes. Includes for instance high performance coordination with robot movement and shared drive unit for several axes. Big Inertia One side effect of the dynamic model concept is that the system can handle very big load inertias by automatically adapting the performance to a suitable level.
Page 108 Serial signals for Single External Axes measurement and drive system Measurement System 1 Not supplied on delivery Multiple External Axes alt. Measurement System 2 Drive System 2 ABB Drives Figure 10 Outline diagram, external axes. Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 109 Description 1.13 I/O System A distributed I/O system is used, based on the fieldbus standard CAN/DeviceNet. This makes it possible to mount the I/O units either inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the cabinet. Two independent CAN/DeviceNet buses allow various conditions of I/O handling.
Page 110 - Distributed I/O-connections inside or on cabinet wall For more detailed information, see Chapter 2, Specification of Variants and Options. ABB I/O units (node types) Several I/O units can be used. The following table shows the maximum number of physical signals that can be used on each unit. Data rate is fixed at 500 Kbit/s.
Page 111 Description Digital Analog Type of unit DSQC Option Voltage Voltage Current Power supply inputs output output Digital I/O 24 VDC Internal/External Digital I/O 120 VAC Internal/External Analog I/O Internal AD Combi I/O Internal/External Relay I/O Internal/External Allen-Bradley Remote I/O Slave Interbus Slave 242-285 Profibus DP Slave...
Page 112 Description Signal data Permitted customer 24 V DC load max. 7,5 A Digital inputs (option 201/203) 24 V DC Optically-isolated Rated voltage: 24 V DC Logical voltage levels: “1” 15 to 35 V “0” -35 to 5 V Input current at rated input voltage: 6 mA Potential difference: max.
Page 113 Description Digital outputs 120 V AC (option 204) Optically isolated, voltage spike protection Rated voltage 120 V AC Output current: max. 1A/channel, 12 A 16 channels max. 2A/channel, 10 A 16 channels (56 A in 20 ms) min. 30mA Voltage range: 24 to 140 V AC Potential difference: max.
Page 114 Description Digital inputs Motors on/off Starts program from where it is Motors on and program start Starts program from the beginning Stops program Stops program when the program cycle is ready Stops program after current instruction Executes “trap routine” without affecting status of stopped regular program Loads and starts program from the beginning Resets error...
Page 115 Description 1.14 Communication The controller has three serial channels for permanent use - two RS232 and one RS422 Full duplex - which can be used for communication point to point with printers, terminals, computers and other equipment. For temporary use, like service, there are two more RS 232 channels.
Page 116 Description Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 117 Specification of Variants and Options 2 Specification of Variants and Options The different variants and options for the controller are described below. The same numbers are used here as in the Specification form. For manipulator options, see Product Specification respectively, and for software options, see Product Specification RobotWare Options.
Page 118 Specification of Variants and Options 2 CONTROL SYSTEM CABINET Variant 111 Standard cabinet with upper cover. 112 Prepared for Arcitec Rotary switch 80A (143) and Circuit breaker standard (147) and Arcitec 4.0 (556) are mandatory. Not with Wheels (126) or Mains connection type CEE17 connector (132, 133) or 6HSB (134) or Mains switch Flange disconnector (142) or Servo disconnector (144) or UL (695) or UR (696).
Page 119 Specification of Variants and Options OPERATOR’S PANEL The operator’s panel and teach pendant holder can be installed in different ways. 181 Standard, i.e. on the front of the cabinet. 182 External, i.e. in a separate operator’s unit. (See Figure 15 for required preparation) All necessary cabling, including flange, connectors, sealing strips, screws, etc., is supplied.
Page 120 Specification of Variants and Options M5 (x4) for fastening of box Connection flange Figure 16 Operator’s panel mounted in a box (all dimensions in mm). OPERATOR’S PANEL CABLE 185 15 m 186 22 m 187 30 m DOOR KEYS 461 Standard 462 Doppelbart 463 Square outside 7 mm 464 EMKA DB...
Page 121 Specification of Variants and Options TEACH PENDANT 601 Teach pendant with back lighting, connection cable 10 m. Teach pendant language: 611 English 612 Swedish 613 German 614 French 615 Spanish 616 Portuguese 617 Danish 618 Italian 619 Dutch 620 Japanese 621 Czech 622 Finnish Extension cable for the teach pendant:...
Page 122 Specification of Variants and Options Figure 17 Transformer unit (dimensions in mm). MAINS CONNECTION TYPE The power is connected either inside the cabinet or to a connector on the cabinet’s left-hand side. The cable is not supplied. If option 133-136 is chosen, the female connector (cable part) is included.
Page 123 Specification of Variants and Options capacity 65 kA at 400V, 25 kA at 600V. 143 Rotary switch 80 A. Customer fuses for cable protection required. Included in the option Prepared for Arcitec (112). 144 Servo disconnector. This option adds a rotary switch 40 A to the two contactors in the AC power supply for the drive system.
Page 124 Specification of Variants and Options I/O INTERFACES The standard cabinet can be equipped with up to four I/O units. For more details, see page 23. X6 (CAN 1.2) X7 (CAN 1.3) X8 (CAN 2) Base Connector Unit DSQC 504 CAN 1 CAN 2 NS MS Ph.5-Pol...
Page 125 Specification of Variants and Options 201 Digital 24 VDC I/O: 16 inputs/16 outputs. 202 Analog I/O: 4 inputs/4 outputs. 203 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V). 204 Digital 120 VAC I/O 16 inputs/16 outputs. 205 Digital I/O with relay outputs: 16 inputs/16 outputs.
Page 126 Specification of Variants and Options The slave units can be I/O units with digital and/or analogue signals. They are all controlled via the master part of the DSQC 510 unit. The slave part of the DSQC 510 is normally controlled by an external master on a separate Profibus-DP network.
Page 127 Specification of Variants and Options 243 Profibus DP Slave Up to 128 digital inputs and 128 digital outputs can be transferred serially to a PLC equipped with a Profibus DP interface. The unit reduces the number of I/O units that can be mounted in the cabinet by one.
Page 128 Specification of Variants and Options EN 50022 mounting rail Figure 21 Dimensions for units 221-225. EN 50022 mounting rail Figure 22 Dimension for units 231-234. EXTERNAL AXES IN ROBOT CABINET (not available for IRB 340, IRB 6400PE, IRB 6600, IRB 7600) It is possible to equip the controller with drives for external axes.
Page 129 A special wiring for the three motor combination 394 (IRB 140, 1400, 2400 only) to be used when axis 7 is intended for an ABB Trackmotion. The drive unit in the DC link and the Trackmotion measurement board is then connected to the robot axes computer 1 while the drive unit and the measurement board for motor 8 and 9 is connected to axes computer 2.
Page 130 Specification of Variants and Options specification. The cable between the controller DDU and the welding gun pedestal is selected in the option range 686-687 (different lengths). The customer connector to this cable should be of Industrial Multi-connector type, corresponding to the manipulator CP/CS (see Product Specification IRB 6600/7600).
Page 131 Specification of Variants and Options 704 Twin SG IRB 6400R The option is a combination of two options 701. A distributed drive unit controls the second SG motor. The cabling between the SG SMBs and the controller is selected in the option range 686-689.
Page 132 Specification of Variants and Options 706 RG and T IRB 6400R The option is a combination of 702 and a track motion IRBT 6002S controlled by a distributed drive unit. The cabling between the RG SMB and the controller is selected in the option range 681-684.
Page 133 Specification of Variants and Options Drive unit Motor max Drive unit rated Suitable motor identity current A current A type 11.5-57 5.5-26 14.5 11 - 55A M, L 6 - 30A S, M, L 7.5-37 S, M, L, XL 4 - 19A 8,4A S, M 2,5 - 11A...
Page 134 Specification of Variants and Options EQUIPMENTManipulator cable, external connectors 653 Standard Cable length 641 7m 642 15 m, not available for IRB 140 643 22 m, not available for IRB 140 644 30 m, not available for IRB 140 649 3 m, only available for IRB 140 Manipulator connection (only available for IRB 340) 657 External (not for the SA-version i.e.
Page 135 Specification of Variants and Options will not deteriorate at higher temperatures but there will be an increase in the number of reading/writing problems as the temperature increases. Extended mass memory 310 Flash disc 128 Mb. Standard is 64 Mb Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 136 Specification of Variants and Options Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 137 Index 3 Index event routine 16 explosive environments 12 extended memory 11 external axes 21 absolute measurement 16 external panel 33 Allen-Bradley Remote I/O 23, 25, 40 analog signals 23, 27 automatic operation 15 fire safety 6 flash disk memory 11 fly-by point 14 backup function keys 7...
Page 138 Index mass memory 11 programming 13 memory protection standards 12 backup 11 extended 11 flash disk 11 QuickMove 18 mass storage 11 RAM memory 11 menu keys 7 RAPID Language 16 mirroring 15 reduced speed 5 motion 18 motion keys 7 motion performance 18 Motion Supervision 20 safe manual movements 6...
Page 139 Index variants 31 vibration 12 volume 3 window keys 7 windows 7 working space restricting 6 world coordinate system 19 Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 140 Index Product Specification S4Cplus M2000/BaseWare OS 4.0...
Page 141 Product Specification RobotWare Options 3HAC 9218-1/Rev.2 BaseWare OS 4.0...
Page 142 Products AB, Robotics assumes no responsibility for any errors that may appear in this document. In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.
Page 143 Product Specification RobotWare Options CONTENTS Page 1 Introduction ........................3 2 BaseWare Options ......................5 [544] Absolute Accuracy ..................5 [541] Load Identification and Collision Detection (LidCode) ......7 [542] ScreenViewer ....................9 [532] Multitasking ....................11 [531] Advanced Motion ..................12 [530] Advanced Functions ..................
Page 144 Product Specification RobotWare Options Product Specification RobotWare Options for BaseWare OS 4.0...
Page 145 Introduction 1 Introduction RobotWare is a family of software products from ABB Automation Technology Product AB, Robotics, designed to make you more productive and lower your cost of owning and operating a robot. ABB Automation Technology Product AB, Robotics has invested many man-years into the development of these products and they represent knowledge and experience based on several thousand robot installations.
Page 146 Introduction Product Specification RobotWare Options for BaseWare OS 4.0...
Page 147 Inherent mechanical tolerances and deflection due to load in the robot structure decrease the robot’s absolute accuracy. Practical compensation of such errors is a complex and highly non-linear problem. The ABB solution is to compensate positions internally in the controller, resulting in a defined and measurable robot TCP (Tool Center Point) accuracy.
Page 148 Absolute Accuracy. Absolute Accuracy functionality may also be deactivated. Both actions require a cabinet restart. Supported robot types Please contact your local ABB office in order to get the latest list of supported robot types. RAPID instructions included in this option No specific RAPID instructions are included.
Page 149 [541] Load Identification and Collision Detection (LidCode) [541] Load Identification and Collision Detection (LidCode) This option is available for the following robot families: IRB 140, IRB 1400, IRB 2400, IRB 4400, IRB 6400 (not 640) IRB 7600 and for external manipulators IRBP-L, IRBP-K, IRBP-R and IRBP-A.
Page 150 [541] Load Identification and Collision Detection (LidCode) ParIdPosValid Checking that the current position is OK for identification. LoadId Performing identification. MechUnitLoad Definition of payload for external mechanical units. Product Specification RobotWare Options for BaseWare OS 4.0...
Page 151 [542] ScreenViewer [542] ScreenViewer This option adds a user window to display user defined screens with advanced display functions. The user window can be displayed at any time, regardless of the execution state of the RAPID programs. User defined screens The user defined screens are composed of: •...
Page 152 [542] ScreenViewer A screen event can occur - When a new screen is displayed (to initialize the screen contents). - After a chosen interval (to refresh a screen). - When a menu choice or a function key is selected (to execute a specific action, or change the screen).
Page 153 [532] Multitasking [532] Multitasking Up to 10 programs (tasks) can be executed in parallel with the normal robot program. - These additional tasks start automatically at power on and will continue until the robot is powered off, i.e. even when the main process has been stopped and in manual mode.
Page 154 (see User’s Guide, Calibration). For other types of manipulators/robot carriers, comprising up to six linear and/or rotating axes, a special configuration file is needed. Please contact your nearest local ABB office. Contour tracking Path corrections can be made in the path coordinate system. These corrections will take effect immediately, also during movement between two positions.
Page 155 [531] Advanced Motion Independent movements A linear or rotating axis can be run independently of the other axes in the robot system. The independent movement can be programmed as an absolute or relative position. A continuous movement with a specific speed can also be programmed. Examples of applications: - A robot is working with two different stations (external axes).
Page 156 [530] Advanced Functions [530] Advanced Functions Includes functions making the following possible: - Information transfer via serial channels or files. - Setting an output at a specific position. - Checking signal value at a specific position. - Executing a routine at a specific position. - Defining forbidden areas within the robot´s working space.
Page 157 [530] Advanced Functions Fixed position output The value of an output (digital, analog or a group of digitals) can be ordered to change at a certain distance before or after a programmed position. The output will then change at the same place every time, irrespective of the robot’s speed. Consideration can also be given to time delays in the process equipment.
Page 158 [530] Advanced Functions World Zones A spherical, cylindrical or cubical volume can be defined within the working space. When the robot reaches this volume it will either set an output or stop with the error message “Outside working range”, both during program execution and when the robot is jogged into this area.
Page 159 [530] Advanced Functions Example: - Output 1 = Input 2 AND Output 5. - Input 3 = Output 7 OR NOT Output 8. Examples of applications: - Program execution to be interrupted when both inputs 3 and 4 become high. - A register is to be incremented when input 5 is set, but only when output 5=1 and input 3=0.
Page 160 [530] Advanced Functions MoveJSync Position fix procedure call during joint movement ISignalAI Interrupts from analog input signal ISignalAO Interrupts from analog output signal Product Specification RobotWare Options for BaseWare OS 4.0...
Page 161 [537] Developer’s Function [537] Developer’s Function This option is intended to be used by application developers requiring more advanced functions than normally available for an end user. The package includes a detailed reference manual on the RAPID language kernel and a number of instruction and function groups useful for different application development as listed below.
Page 162 [537] Developer’s Function Data Search Functions With these functions it is possible to search all data in a RAPID program, where the name or the data type is given as a text string. This might be useful for instance in the following examples: - A common problem is to check if a data with a certain name is declared in the system, and in such case what is its value, e.g.a robtarget...
Page 163 [537] Developer’s Function IsStopStateEvent Function which will return information about the movement of the Program Pointer (PP). ReadCfgData Read system configuration data. WriteCfgData Write system configuration data. Power Failure Functions The package is used to get I/O signal values before power failure and to reset them at power on.
Page 164 [537] Developer’s Function FileSize Get the size of a file FSSize Get the size of a file system Product Specification RobotWare Options for BaseWare OS 4.0...
Page 165 [558] Discrete Application [558] Discrete Application Discrete Applications Platform (DAP) is a software platform for time critical applications, where certain actions shall be performed at specific robot positions. Target users are advanced application software engineers and system integrators, e.g. for spot welding, drilling, measuring, quality control. The main advantages are achieved in the following areas: - Development time - Program execution time.
Page 166 [540] Conveyor Tracking [540] Conveyor Tracking Conveyor Tracking (also called Line Tracking) is the function whereby the robot follows a work object which is mounted on a moving conveyor. While tracking the conveyor, the programmed TCP speed relative to the work object will be maintained, even when the conveyor speed is changing slowly.
Page 167 [533] Electronically Linked Motors [533] Electronically Linked Motors This option is used to make master/slave configurations of motors, which are defined as external axes. The main application is to replace mechanical driving shafts of Gantry machines, but the option can be used to control any other set of motors as well. Features •...
Page 168 [547]Sensor Synchronization [547] Sensor Synchronization Sensor Synchronization adjusts the robot speed to an external moving device (e.g. a press or conveyor) with the help of a sensor. This option simplifies programming and improves productivity of any loading /unloading application since it provides automatic sensor status check and speed adjustment.
Page 169 [539] Sensor Interface [539] Sensor Interface The Sensor Interface option can be used to integrate sensor equipment for adaptive control, like path correction or process tuning. The option includes a driver for serial communication with the sensor system using a specific link protocol (RTP1) and a specific application protocol (LTAPP).
Page 170 [561] Servo Tool Control [561] Servo Tool Control The Servo Tool Control is a general and flexible software platform for controlling an integrated servo tool from S4CPlus. For additional features, like control of external processes, or control of several ServoGuns in parallel, please refer to the option SpotWare Servo.
Page 171 [561] Servo Tool Control Rapid instructions included in this option STClose Close a Servo Tool with a predefined force and thickness STOpen Open a Servo Tool STCalib Calibrate a Servo Tool STTune Tune motion parameters for a Servo Tool STTuneReset Reset tuned motion parameters STIsClosed Test if a Servo Tool is closed...
Page 172 [631] Servo Tool Change [631] Servo Tool Change Servo Tool Change enables an on-line change of tools (external axes), for a certain drive- and measurement system. The control is switched between the axes by switching the motor cables from one servo motor to another. The switch is performed on-line, during production. The main advantages are: - Flexibility in the production process One robot handles several tools...
Page 173 [631] Servo Tool Change The motor position at the moment of deactivation of one axis is saved and restored next time the axis is activated. Note: The motor position must not change more than half a motor revolution, when the axis is disconnected. In SpotWare Servo, there is a calibration routine, which handles larger position changes.
Page 174 [535] RAP Communication [535] RAP Communication This option is required for all communication with a superior computer, where none of the WebWare products are used. It includes the same functionality described for the option Factory Ware Interface. It also works for the WebWare products. There is no difference from the FactoryWare Interface (except that the price is higher).
Page 175 [543] Ethernet Services [543] Ethernet Services This option includes the same functionality as described for Ethernet Services NFS except that the protocol used for remote mounted disc functionality is FTP. The aspect of authorization differs between NFS and FTP. Examples of applications: - All programs for the robot are stored in the PC.
Page 176 [534] FactoryWare Interface [534] FactoryWare Interface This option enables the robot system to communicate with a PC. FactoryWare Interface serves as a run-time license for WebWare, i.e. the PC does not require any license protection when executing a WebWare based application. Factory Ware Interface includes the Robot Application Protocol (RAP).
Page 177 [271] Interbus-S Configuration Tool [271] Interbus Configuration Tool The Interbus Configuration Tool is used to configure the communication channels of the DSQC 512 board. (See ‘I/O Interfaces’, in the S4Cplus Product Specification.) The tool consists of standard PC software. The tool creates a bus configuration, which is used by the controller.
Page 178 [270] Profibus DP Configuration Tool [270] Profibus DP Configuration Tool The Profibus Configuration Tool is used to configure the master channel of the Profibus DP DSQC 510 board. (See ‘I/O Interfaces’, in the S4Cplus Product Specification.) The tool consists of standard PC software. The tool creates a bus configuration, which is used in the robot controller.
Page 179 [538] I/O Plus [538] I/O Plus I/O Plus enables the S4Cplus to use non-ABB I/O units. The following units are supported: - Wago modules with DeviceNet fieldbus coupler, item 750-306 revision 3. - Lutze IP67 module DIOPLEX-LS-DN 16E 744-215 revision 2 (16 digital input signals).
Page 180 [551] ArcWare 3 ProcessWare [551] ArcWare ArcWare comprises a large number of dedicated arc welding functions, which make the robot well suited for arc welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction.
Page 181 Seam finding and tracking Seam finding and tracking can be implemented using a number of different types of sensors. Please contact your nearest local ABB office for more information. Interface signals The following process signals are, if installed, handled automatically by ArcWare. The robot can also support dedicated signals for workpiece manipulators and sensors.
Page 182 [551] ArcWare Analog inputs (cont.) Description (cont.) Voltage Weld voltage measurement for monitoring and supervision Current Weld current measurement for monitoring and supervision RAPID instructions included in this option ArcL Arc welding with linear movement ArcC Arc welding with circular movement ArcKill Aborts the process and is intended to be used in error handlers...
Page 183 [552] ArcWare Plus [552] ArcWare Plus ArcWare Plus contains the following functionality: - ArcWare, see previous chapter. - Arc data monitoring. Arc data monitoring with adapted RAPID instructions for process supervision. The function predicts weld errors. - Contour tracking during welding. Path corrections during welding, i.e.
Page 184 [556] Arcitec [556] Arcitec This option is intended to be used in combination with the Arcitec power sources. It shall only be ordered by the supplying unit of Arcitec. The package is a special software, used together with the ArcWare package, to be able to control not only the robot program but also the set up, configuration and programming of the power source.
Page 185 [553] SpotWare [553] SpotWare The Spotweld options are general and flexible software platforms for creation of customized and easy to use function packages for different types of spotweld systems and process equipments. The SpotWare option is used for sequential welding with one or several pneumatic gun equipments.
Page 186 [553] SpotWare Principles of SpotWare The SpotWare functions will be controlled by separate internal program processes, which will run in parallel. For instance the robot movements, the continuous super- vision and the spot welding will be handled in different independent processes. This means that if for instance the program execution and thus the robot movements is stopped, then the welding and supervision will continue until they come to a well defined process stop.
Page 187 [554] SpotWare Plus [554] SpotWare Plus The SpotWare Plus package provides support for sequential welding with one or several pneumatic on/off gun equipments, as the SpotWare package, but also welding and full individual monitoring of up to four separate gun equipments at the same time. SpotWare Plus features The SpotWare Plus package contains the same features as SpotWare but with following feature in addition:...
Page 188 [554] SpotWare Plus Spot welding instructions Instruction Used to: SpotML Control the motion, gun closure/opening and 1 - 4 welding processes. Move the TCP along a linear path and perform spot welding with 1 - 4 gun equipments at the end position. SpotMJ Control the motion, gun closure/opening and 1 - 4 welding processes.
Page 189 [625] SpotWare Servo [625] SpotWare Servo The Spotweld options are general and flexible software platforms for creation of customized and easy to use function packages for different types of spotweld systems and process equipments. The SpotWare Servo option is used for sequential welding with one or two servo gun equipments.
Page 190 [625] SpotWare Servo - Fast switch between two servo guns with a tool changer. Note: This feature requires the Servo Tool Change option. Principles of SpotWare Servo The SpotWare functions will be controlled by separate internal program processes, which will run in parallel. For instance the robot movements, the continuous supervision and the spotwelding will be handled in different independent processes.
Page 191 [625] SpotWare Servo Spot welding instructions Instruction Used to: SpotL Control the motion, gun closure/opening and the welding process. Move the TCP along a linear path and perform a spot welding at the end position. SpotJ Control the motion, gun closure/opening and the welding process.
Page 192 [626] SpotWare Servo Plus [626] SpotWare Servo Plus The SpotWare Servo Plus package provides support for sequential welding with one or several servo gun equipments, as the SpotWare Servo package, but also welding with two servo guns at the same time. SpotWare Servo Plus features The SpotWare Servo Plus package contains the same features as SpotWareServo but with following feature in addition:...
Page 193 [626] SpotWare Servo Plus Instruction Used to: SpotML Control the motion, gun closure/opening and 1 - 2 welding processes. Move the TCP along a linear path and perform spot welding with 1 - 2 gun equipments at the end position. SpotMJ Control the motion, gun closure/opening and 1 - 2 welding processes.
Page 194 [569] DispenseWare [569] DispenseWare The DispenseWare package provides support for different types of dispensing processes such as gluing and sealing. The DispenseWare application provides fast and accurate positioning combined with a flexible process control. Communication with the dispensing equipment is carried out by means of digital and analog outputs.
Page 195 [569] DispenseWare The gluing process is specified by: - Bead specific dispensing data. See Data types - beaddata. - Equipment specific dispensing data. See Data types - equipdata. - RAPID routines and global data for customizing purposes. See Predefined Data and Programs - System Module DPUSER.
Page 196 [571] PalletWare [571] PalletWare General PalletWare is a ready-to-use software package for the S4Cplus controller, focused on palletizing. PalletWare imports data created with PalletWizard, the included off-line PC-tool, to execute the defined palletizing cycles. PalletWare has a predefined interface for connecting PLC (Programmable Logic Controller), which is the most common way to control external equipment such as infeeders, outfeeders and sensor equipment.
Page 197 [571] PalletWare - Tool control - Standardized error handling - Predefined user routines Programming principles PalletWare is added to the BaseWare system. PalletWare consists of predefined motion principles and communication routines for communicating with external equipment. It is not necessarily needed to implement any RAPID code. However, the system supports integrators for customizing by standardized functions and instructions.
Page 198 [571] PalletWare PalletWizard offers for example the following features: - Detailed On-line help - Wizards for defining the products, tools, cell definition, station configurations, pallet composition and the pallet cycles - Automatic pick- and place definition - Automatic calculating of grip zones to be used for the tool - Software based collision detection - Library of predefined patterns Several different pallet cycles can be combined into a production cycle and saved into...
Page 199 Index INDEX 4 Index output 15 procedure call 15 Friction Compensation 13 FTP 32 AbsAcc 5 Absolute Accuracy 5 I/O Plus 36 Advanced functions 14 independent movement 13 arc welding 37, 40 input or output signals Arcitec 41 interrupts 17 ArcWare 37 Interbus Configuration Tool 34 ArcWare Plus 40...
Page 200 Index Reset the work area 12 Sensor Interface 26 Sensor Synchronization 25 serial channel 14 Servo Tool Change 29 Servo Tool Control 27 SpotWare Servo 46 SpotWare Servo Plus 49 transfer data 14, 33 file 33 program 33 World Zones 16 write data 14 file 14...
Page 201 Installation Manual, IRB 6600/6650, M2000A 3HAC 16245-1 Revision A...
Page 202 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re- sponsibility for any errors that may appear in this manual. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.
Page 203 3.0.1 Pre-installation procedure ........... .27 3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55 ..... . .30 3.0.3 Working range, IRB 6600 - 175/2.8.
Page 204 Table of Contents Section 4.2: Restricting the working range..........61 4.2.1 Introduction .
Page 205 Table of Contents Chapter 7: Installation of controller software 7.0.1 Loading system software ........... .141 7.0.2 RobotWare CD-ROM .
Page 206 Table of Contents Chapter 11: Decommissioning 11.0.1 Balancing device, IRB 7600 and IRB 6600/6650 ....... . 205 3HAC 16245-1...
Page 207 0.0.1 Overview 0.0.1 Overview About This This information product is a manual containing instructions for installing the complete robot Manual system, mechanically as well as electrically. Usage This manual should be used during installation, from lifting the manipulator to its work site thru installing application software in the robot controller, making the robot ready for opera- tion.
Page 208 0.0.1 Overview Revisions Revision Description First edition • Various corrections in text and in figures due to reconstruc- tions, new options, etc. • Manual completed with references to pagenumbers and numbering of sections (manipulator sections). • Manual completed with version IRB 6650. 3HAC 16245-1...
Page 209 The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during oper- ation. A complete listing of all available software manuals is available from ABB Robotics. 3HAC 16245-1...
Page 210 0.0.2 Product Documentation Hardware option Each hardware option is supplied with its own documentation. Each document set contains manual the types of information specified above: • Installation information • Repair information • Maintenance information In addition, spare part information is supplied for the complete option. 3HAC 16245-1...
Page 211 1 Safety, service 1.0.1 Introduction Chapter 1: Safety, service 1.0.1 Introduction Definitions This chapter details safety information for service personnel i.e. personnel performing instal- lation, repair and maintenance work. Sections The chapter "Safety, service" is divided into the following sections: 1.
Page 212 General Any information given in this information product regarding safety, must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with. 1.1.3 Related information...
Page 213 1 Safety, service 1.2.1 Safety risks related to gripper Section 1.2: Safety risks 1.2.1 Safety risks related to gripper Ensure that a gripper is prevented from dropping a workpiece, if such is used. 1.2.2 Safety risks related to tools/workpieces Safe handling It must be possible to turn off tools, such as milling cutters, etc., safely.
Page 214 Nation/region To prevent injuries and damage during the installation of the robot system, the regulations specific regula- applicable in the country concerned and the instructions of ABB Robotics must be complied tions with. Non-voltage •...
Page 215 1 Safety, service 1.2.6 Risks associated with live electric parts • Units inside the controller, e.g. I/O modules, can be supplied with power from an exter- nal source. • The mains supply/mains switch • The power unit • The power supply unit for the computer system (230 VAC) •...
Page 216 1 Safety, service 1.3.1 Safety fence dimensions Section 1.3: Safety actions 1.3.1 Safety fence dimensions General Fit a safety fence or enclosure around the robot to ensure a safe robot installation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.
Page 217 1 Safety, service 1.3.5 Risk of disabling function "Reduced speed 250 mm/s" 1.3.5 Risk of disabling function "Reduced speed 250 mm/s" Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. 1.3.6 Safe use of the Teach Pendant Unit The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON.
Page 218 1 Safety, service 1.3.7 Work inside the manipulator’s working range 3HAC 16245-1...
Page 219 2 Reference information 2.0.1 Introduction Chapter 2: Reference information 2.0.1 Introduction General This chapter presents generic pieces of information, complementing the more specific infor- mation in the following chapters. 3HAC 16245-1...
Page 220 2 Reference information 2.1.1 Applicable Safety Standards Section 2.1: Reference information 2.1.1 Applicable Safety Standards Standards, The robot is designed in accordance with the requirements of: general • EN 775 - Robot safety. • EN 292-1 - Basic terminology. • EN 292-2 - Technical principles.
Page 221 UNBRAKO UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It fea- screws tures special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
Page 222 2 Reference information 2.1.2 Screw joints Tightening torque Below are tables specifying the torque values for different screw joint types: Screws with slot- ted or cross recess head Tightening torque (Nm) Dimension Class 4.8 "dry" M2.5 0.25 Screws with hexagon socket head, “dry”...
Page 223 All components exceeding 22 kg (50 lbs) are high-lighted in this way. ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is avail- able for each manipulator model.
Page 224 2 Reference information 2.1.4 Standard toolkit 2.1.4 Standard toolkit General All service (repairs, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools required are listed directly in the instructions while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.
Page 225 2 Reference information 2.1.5 Special tools 2.1.5 Special tools General All service (repairs, maintenance and installation) instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 22, and of special tools, listed directly in the instructions and also gathered in the table below.
Page 226 2 Reference information 2.1.5 Special tools Description IRB 66X0/Qty IRB 7600/Qty Art. no. Hydraulic pump 80Mpa (Glycerin) 3HAC 13086-2 Levelmeter 2000 kit 6369901-348 Lifting device, base 3HAC 15560-1 Lifting device, manipulator 3HAC 15607-1 Lifting device, upper arm 3HAC 15994-1 Lifting device, upper arm 3HAC 15536-1 Lifting eye VLBG M12 3HAC 16131-1...
Page 227 2 Reference information 2.1.6 Performing a leak-down test 2.1.6 Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equip- ment Equipment, etc.
Page 228 2 Reference information 2.1.7 Lifting equipment and lifting instructions 2.1.7 Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each activity instruction. However, how to use each piece of lifting equipment is not detailed in the activity instruction, but in the instruction delivered with each piece of lifting equipment.
Page 229 Lifting manipulator with fork lift on page 36. Weight, manipu- The table below shows the weights of the different models: lator Manipulator model Weight IRB 6600 - 175/2.55 1700 kg IRB 6600 - 225/2.55 1700 kg IRB 6600 - 175/2.8 1700 kg IRB 6650 - 125/3.2...
Page 230 Max. tilt 5° The limit for the maximum payload on the manipulator is reduced if the manipulator is tilted from 0°. Contact ABB for further information about acceptable payload. Min. resonance frequency 22 Hz Storage condi- The table below shows the allowed storage conditions for the manipulator:...
Page 231 3 Unpacking 3.0.1 Pre-installation procedure Protection The table below shows the protection class of the manipulator: classes, manipu- lator Equipment Protection class Manipulator, IRB 6600/6650 IP 67 3HAC 16245-1...
Page 232 3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55 3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55 Illustration The illustration below shows the unrestricted working range of IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55: IR B 6600-175/2,55...
Page 233 3 Unpacking 3.0.3 Working range, IRB 6600 - 175/2.8 3.0.3 Working range, IRB 6600 - 175/2.8 Illustration The illustration below shows the unrestricted working range of IRB 6600 - 175/2.8: IR B 6600-175/2,8 1324 1004 2061 2800 xx0200000026 3HAC 16245-1...
Page 234 3 Unpacking 3.0.4 Working range, IRB 6650 - 125/3.2 3.0.4 Working range, IRB 6650 - 125/3.2 Illustration The illustration below shows the unrestricted working range of IRB 6650 - 125/3.2: IRB 6650-125/3.2 xx0200000338 3HAC 16245-1...
Page 235 3 Unpacking 3.0.5 Working range, IRB 6650 - 200/2.75 3.0.5 Working range, IRB 6650 - 200/2.75 Illustration The illustration below shows the unrestricted working range of IRB 6650 - 200/2.75: RB 6650-200/2.75 xx0200000339 3HAC 16245-1...
Page 236 3 Unpacking 3.0.6 Risk of tipping/Stability 3.0.6 Risk of tipping/Stability Risk of tipping When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. Moving the arms will displace the centre of gravity, which may cause the manipulator to tip over.
Page 237 4 On-site Installation Chapter 4: On-site Installation 3HAC 16245-1...
Page 238 4 On-site Installation 4.1.1 Lifting manipulator with fork lift Section 4.1: On-site installation, manipulator 4.1.1 Lifting manipulator with fork lift General The manipulator may be moved using a fork lift. Special aids are available. This section applies to the IRB 7600 as well as IRB 6600. Different designs There are two different versions of the fork lift that fit one design of the frame respectevily.
Page 239 4 On-site Installation 4.1.1 Lifting manipulator with fork lift Equipment, etc. Art. no. Note Standard toolkit 3HAC 15557-1 The contents are defined in section Stan- dard toolkit on page 18. Illustration, 3HAC The figure below shows how to attach the fork lift set, 3HAC 0604-2, to the manipulator. 0604-2 xx0100000102 Securing screws (2x4 pcs)
Page 240 4 On-site Installation 4.1.1 Lifting manipulator with fork lift Illustration, 3HAC The figure below shows how to attach the fork lift set, 3HAC 0604-1, to the manipulator. 0604-1 xx0200000379 Fork lift pocket (2 pcs, different from each other) Spacer (2 pcs) Securing screws (2x4 pcs), not oil lubricated Securing screws (2 pcs), oil lubricated Attachment point for spacer...
Page 241 4 On-site Installation 4.1.1 Lifting manipulator with fork lift No personnel must under any circumstances be present under the suspended load! Step Action Info/Illustration Make sure the manipulator is posi- Release the brakes if required as detailed in tioned as shown in the figure to the Manually releasing the brakes on page 44.
Page 242 4 On-site Installation 4.1.1 Lifting manipulator with fork lift Step Action Info/Illustration Secure the fork lift pocket vertically by Shown in the figure Illustration, 3HAC 0604- fastening the two washers and oil 1 on page 38! lubricated securing screws to the 2 pcs;...
Page 243 4 On-site Installation 4.1.2 Lifting manipulator with roundslings 4.1.2 Lifting manipulator with roundslings General The manipulator may be lifted with roundslings according to the illustration below. The illus- tration is the same as the label attached to the manipulator´s lower arm. L IF T ING OF R OB OT HE B E N DE S R OB OT E R S L E VAGE DU R OB OT...
Page 244 4 On-site Installation 4.1.3 Lifting manipulator with lifting slings 4.1.3 Lifting manipulator with lifting slings General The section below applies to IRB 7600 as well as IRB 6600. Illustration, lifting The figure below shows how to lift the complete manipulator with lifting slings. slings Note the recommended manipulator position shown in the following figure and in the instruc- tion! Attempting to lift a manipulator in any other position may result in the manipulator...
Page 245 4 On-site Installation 4.1.3 Lifting manipulator with lifting slings Required equip- ment Equipment Art. no. Lifting device, manipulator 3HAC 15607-1, includes instruction, 3HAC 15971-2, for how to use the lifting device. Slings attached The section below details how to lift and move the manipulator using lifting slings when these directly onto are to be attached directly onto the manipulator frame.
Page 246 4 On-site Installation 4.1.4 Manually releasing the brakes 4.1.4 Manually releasing the brakes General The section below details how to release the holding brakes of each axis motor. It applies to IRB 7600 as well as IRB 6600/6650. Differences between the versions are highlighted in the affected sections.
Page 247 4 On-site Installation 4.1.4 Manually releasing the brakes Illustration, IRB The internal brake release unit on the IRB 7600 is located either at the base or at the frame. 7600 base The figure below shows the unit located at the base. xx0200000375 Internal brake release unit with push buttons, located on the manipulator base Illustration, IRB...
Page 248 4 On-site Installation 4.1.4 Manually releasing the brakes Internal brake The procedure below details how to release the holding brakes when the robot is equipped release unit, with an internal brake release unit. releasing the brakes When relasing the holding brakes, the manipulator axes may move very quickly and some- times in unexpected ways! Make sure no personnel is near the manipulator arm! Step Action...
Page 249 4 On-site Installation 4.1.4 Manually releasing the brakes Illustration IRB The illustration below shows the connectors on the manipulator and on the external brake 7600, external release unit. brake release unit connectors xx0200000081 Rear connector plate Connector R1.MP Connector R1.BU External brake release unit Connect to R1.BU Required equip-...
Page 250 4 On-site Installation 4.1.4 Manually releasing the brakes Step Action Info/Illustration Locate the free connector, connected to the Shown in Illustration IRB 7600, exter- rear of connector R1.MP behind the rear nal brake release unit connectors on connector plate. page 47! Make sure it is designated R1.BU.
Page 251 4 On-site Installation 4.1.5 Lifting the base plate 4.1.5 Lifting the base plate General This section details how to lift the base plate Equipment Spare part no. Art. no. Note Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Lifting eye, M16 3HAC 14457-4 Use three lifting eyes.
Page 252 4 On-site Installation 4.1.6 Securing the base plate 4.1.6 Securing the base plate General This section details how to secure the base plate. Base plate, 2x 503 2x 451 dimensions 2x 453 2x 407 2x 247 2x 321 2x 182 2x 273 2x 90 2x 90 B- B...
Page 253 Note Base plate 3HAC 12937-7 Includes all required guide sleeves, screws and washers. A drawing of the base plate itself may be ordered from ABB Robotics! Guide sleeves, 2 pcs 3HAC 12937-3 Included in Base plate, 3HAC (between guide plate 12937-7.
Page 254 4 On-site Installation 4.1.6 Securing the base plate Base plate This section details how to secure the base plate to the foundation. The table specifies any recommendations made by ABB: Variable Recommendation Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3,...
Page 255 4 On-site Installation 4.1.7 Orienting and securing the manipulator 4.1.7 Orienting and securing the manipulator General This section details how to orient and secure the manipulator to the base plate after fitting it to the foundation, in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures.
Page 256 4 On-site Installation 4.1.7 Orienting and securing the manipulator Securing the The procedure below details how to secure the manipulator to the base plate after fitting the manipulator plate to the foundation. Step Action Info/Illustration Lift the manipulator. Detailed in Lifting manipulator with fork lift on page 36or Lifting manipulator with lifting slings on page 42.
Page 257 4 On-site Installation 4.1.7 Orienting and securing the manipulator Hole configura- The illustration below shows the hole configuration used when securing the manipulator, IRB tion, IRB 7600 7600. xx0300000046 Cross section, The illustration below shows the cross section of the guide sleeve holes. guide sleeve hole xx0100000109 3HAC 16245-1...
Page 258 4 On-site Installation 4.1.8 Fitting equipment on manipulator 4.1.8 Fitting equipment on manipulator General The manipulator features mounting holes for additional equipment. Access to any of the following mounting holes may be obstructed by any additional cabling, equipment etc, fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell.
Page 259 4 On-site Installation 4.1.8 Fitting equipment on manipulator Illustration, fitting The illustration below shows the mounting holes available for fitting extra equipment on the extra equipment frame. on frame 4x M16 1195 xx0200000198 3HAC 16245-1...
Page 260 4 On-site Installation 4.1.8 Fitting equipment on manipulator Illustration, fitting The illustrations below show the mounting holes available for fitting equipment on the on mounting mounting flange. There are two different versions of the mounting flange, as shown in illus- flange trations below.
Page 261 4 On-site Installation 4.1.8 Fitting equipment on manipulator 30° (12 x) Ø12 H7 Depth 15 Ø100H7 Depth 8min Ø160 xx0200000397 Mounting flange for robot version 175/2.55 Fastener quality When fitting tools on the mounting flange (see the figures above), use only screws with qual- ity 12.9.
Page 262 Product Specification. The loads must also be defined in the software as detailed in User’s Guide. Stop time and Manipulator motor brake performance depends on any loads attached. For further informa- braking distances tion about brake performance, please contact ABB Robotics. 3HAC 16245-1...
Page 263 4 On-site Installation 4.2.1 Introduction Section 4.2: Restricting the working range 4.2.1 Introduction General The working range of the manipulator may be limited to eliminate the risk of collisions. The following axes may be restricted: • Axis 1, hardware (mechanical stop) and software (signal from adjustable position switch) •...
Page 264 4 On-site Installation 4.2.2 Mechanically restricting the working range of axis 1 4.2.2 Mechanically restricting the working range of axis 1 General The working range of axes 1 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation in both directions. Mechanical The illustration below shows the mounting position of the mechanical stops on axis 1.
Page 265 4 On-site Installation 4.2.2 Mechanically restricting the working range of axis 1 Installation, The procedure below details how to mount the mechanical stops on axis 1. An assembly mechanical stops drawing is also enclosed with the product. axis 1 The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed! Step Action...
Page 266 4 On-site Installation 4.2.3 Mechanically restricting the working range of axis 2 4.2.3 Mechanically restricting the working range of axis 2 General The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction. Mechanical The illustration below shows the mounting position of the mechanical stops on axis 2.
Page 267 4 On-site Installation 4.2.3 Mechanically restricting the working range of axis 2 Installation, The procedure below details how to mount the mechanical stops on axis 2. An assembly mechanical stops drawing is also enclosed with the product. axis 2 The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed! Step Action...
Page 268 4 On-site Installation 4.2.4 Mechanically restricting the working range of axis 3 4.2.4 Mechanically restricting the working range of axis 3 General The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction. Mechanical The illustration below shows the mounting position of the mechanical stops on axis 3.
Page 269 4 On-site Installation 4.2.4 Mechanically restricting the working range of axis 3 Installation, The procedure below details how to mount the mechanical stops on axis 3. An assembly mechanical stops drawing is also enclosed with the product. axis 3 The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed! Step Action...
Page 270 The position switch kits may be delivered in one of two ways: • Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.
Page 271 4 On-site Installation 4.2.5 Position switches Axis 2 The illustration below shows the position switch for axis 2: xx0100000159 Position switch, axis 2 Set screw, cam (cam stop) Rail Rail Attachment 3HAC 16245-1...
Page 272 4 On-site Installation 4.2.5 Position switches Axis 3 The illustration below shows the position switch for axis 3: xx0100000160 Position switch, axis 3 Set screw, cam (cam stop) Rail Rail attachment Specifications Maximum voltage/current for the position switches: Parameter Value Voltage Max.
Page 273 4 On-site Installation 4.2.5 Position switches Fitting and The instruction below details how to fit and adjust the parts of the position switches: adjusting cams and stops Step Action Info/Illustration Cut the cam to a suitable length. Use a sharp knife and rubber ham- mer or similar.
Page 274 4 On-site Installation 4.2.5 Position switches Illustration, cut- The illustration below show how to cut the position switch cam. ting the cam xx0100000114 Remove the gray section 3HAC 16245-1...
Page 275 4 On-site Installation 4.3.1 Lifting the controller cabinet Section 4.3: On-site installation, controller cabinet 4.3.1 Lifting the controller cabinet Lifting device Use the four lifting devices on the cabinet or a fork lift when lifting the controller cabinet S4Cplus M2000A as shown below. 60°...
Page 276 4 On-site Installation 4.3.2 Required installation space, control cabinet 4.3.2 Required installation space, control cabinet Dimensions The figure below shows the required installation space for the S4Cplus M2000A control cab- inet: xx0100000156 Min. distance from wall Dimensions The figure below shows the bolt pattern for the S4Cplus M2000A control cabinet: xx0100000157 3HAC 16245-1...
Page 277 5 Electrical connections Chapter 5: Electrical connections 3HAC 16245-1...
Page 278 5 Electrical connections 5.1.1 Connecting the manipulator to the control cabinet Section 5.1: Signal/Power cables 5.1.1 Connecting the manipulator to the control cabinet General Connect the manipulator and control cabinet to each other after securing them to the founda- tion. The lists below specify which cables to be used in each application. Location of con- nectors Application interface...
Page 279 5 Electrical connections 5.1.1 Connecting the manipulator to the control cabinet These categories are divided into sub-categories which are specified below: Manipulator These cables are included in the standard delivery. They are completely pre- cables manufactured and ready to plug in. Connection Connection Cable sub-...
Page 280 5 Electrical connections 5.1.1 Connecting the manipulator to the control cabinet Customer cables These cables are not included in the standard delivery, but can be included in the delivery of each specific option. The cables are not ready to plug in, but requires connection to terminals inside the control cabinet as well as keying.
Page 281 5 Electrical connections 5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A 5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A General Section "Connecting the manipulator to the control cabinet" specifies which cables to use and to which connectors these are to be connected in order to to connect the controller to the manipulator.
Page 282 5 Electrical connections 5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A 5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A General Connect the power supply either inside the cabinet, or to a optional socket on the left-hand side of the cabinet or the lower section of the front.
Page 283 5 Electrical connections 5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A Step Action Info/Illustration Connect phase: Shown in the figure above! • 1 to L1 (Not dependent on phase sequence) NOTE! Max. conductor size is 6 mm2 (AWG 10). Tighten to •...
Page 284 5 Electrical connections 5.2.1 Signal Classes Section 5.2: Signal connections 5.2.1 Signal Classes Overview Different rules apply to the different classes when selecting and laying cable. Signals from different classes must not be mixed. Signals • Power Signals: Supplies external motors and brakes. •...
Page 285 A specific cable should be used for Gateway (Fiel bus) connections. CAN bus with Thin cable according to DeviceNet specification release 1.2, must be used, e.g. ABB article DeviceNet for dis- no. 3HAB 8277-1. The cable is shielded and has four conductors, two for electronic supply tributing I/O units: and two for signal transmission.
Page 286 5 Electrical connections 5.2.3 Interference elimination 5.2.3 Interference elimination External units External relay coils, solenoids, and other units that will be connected to the controller must be neutralized. The figure below illustrates how this can be done. The turn-off time for DC relays increases after neutralisation, especially if a diode is connected across the coil.
Page 287 5 Electrical connections 5.2.4 Connection types 5.2.4 Connection types General I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as industrial connectors. Connections Designation Connection type X(T) Screw terminal Pin (male) Sockets (female) 3HAC 16245-1...
Page 288 5 Electrical connections 5.2.5 Connections to screw terminals 5.2.5 Connections to screw terminals Overview This section describes how to connect conductors to screw terminals. Detailed information about connection location and functions will be found in the circuit diagram (Service Man- ual).
Page 289 5 Electrical connections 5.2.6 Connections to connectors (option) 5.2.6 Connections to connectors (option) Location of con- The industrial connectors can be found on the front of the control cabinet. See the figure nectors below and the figure in section "Control cabinet connections manipulator"! The manipulator arm is equipped with round Burndy/Framatome connectors (customer con- nector not included).
Page 290 5 Electrical connections 5.3.1 Signal connections, SpotWelding Specification Section 5.3: Customer connections on manipulator 5.3.1 Signal connections, SpotWelding Specification General The section below specifies the signal connections on manipulator arm housing for material handling. Customer Power (CP) Servo motor power 600 VAC, 12A rms, min.
Page 291 5 Electrical connections 5.3.2 Signal connections, Material Handling Specification 5.3.2 Signal connections, Material Handling Specification General The section below specifies the signal connections on manipulator arm housing for material handling. Customer Power (CP) Servo motor power 600 VAC, 12A rms, min. 1, 5 mm Utility power 600 VAC, 5A rms, min.
Page 292 5 Electrical connections 5.4.1 The MOTORS ON/MOTORS OFF circuit Section 5.4: Customer connections on controller 5.4.1 The MOTORS ON/MOTORS OFF circuit Outline diagram The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches. The diagram shows the available customer connections, AS, GS and ES. xx0100000174 ES (emergency stop) LS (Limit switch)
Page 293 5 Electrical connections 5.4.1 The MOTORS ON/MOTORS OFF circuit Connection of The diagram below shows the two-channel safety chain. safety chains Supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. When external supply of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9 is connected to external 0V. Connection tables for X1-X4 are given in "External customer connections on panel X1 - X4".
Page 294 5 Electrical connections 5.4.1 The MOTORS ON/MOTORS OFF circuit X1:3 X1:7 X1:10 X1:9 X1:8 X1:1 X1:2 X1:6 X2:7 X2:8 X2:1 X2:2 X2:6 X2:4 X2:5 xx0100000191 Internal Run chain 1 top Ext shop Internal ES2 internal Cabinet Run chain 2 top ES1 internal Technical data ES1 and ES2 max output voltage...
Page 295 5 Electrical connections 5.4.1 The MOTORS ON/MOTORS OFF circuit Connection to The diagram below shows the connection of terminals for customer use. MOTORS ON/ MOTORS OFF contactor X3:2 X4:2 xx0100000193 K1 (Motor on/off 1) K1 (Motor on/off 2) Technical data Max.
Page 296 5 Electrical connections 5.4.1 The MOTORS ON/MOTORS OFF circuit Technical data Max. potential in relation to the cabinet 300 V earthing and other signal groups Signal class Control signals Connection to The diagram below shows the connection of terminals for customer use. brake contactor X4:5 xx0100000199...
Page 297 5 Electrical connections 5.4.2 External customer connections on panel X1 - X4 5.4.2 External customer connections on panel X1 - X4 Outline diagram The diagram shows the customer connections X1 - X4 located on the panel unit WARNING REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT xx0100000205 grey field Jumper...
Page 298 5 Electrical connections 5.4.2 External customer connections on panel X1 - X4 Terminal Signal Comment number ES2 out: B Emergency stop out chain 2 ES2 top Top of emergency stop chain 2 0 V emergency stop chain 2 Run ch2 top Top of run chain 2 ES2 internal Internal signal from emergency stop relay chain 2...
Page 299 5 Electrical connections 5.4.2 External customer connections on panel X1 - X4 Terminal Signal Comment number 0 V to auto stop (AS) and general stop (GS) GS2- General stop minus chain 2 AS2- Auto stop minus chain 2 GS2+ General stop plus chain 2 AS2+ Auto stop plus chain 2 24 V panel...
Page 300 5 Electrical connections 5.4.3 Connection of external safety relay 5.4.3 Connection of external safety relay Description The motor contactors K1 and K2 in the controller can operate with external equipment if external relays are used. The figure below shows two examples of how to connect the external safety relays: Connection examples X4:4...
Page 301 5 Electrical connections 5.4.3 Connection of external safety relay To other equipment Safety gate Cell ES (emergency stop) 3HAC 16245-1...
Page 302 5 Electrical connections 5.5.1 External 24V supply Section 5.5: Supplies 5.5.1 External 24V supply When is an exter- An external supply is recommended to make use of the advantages offered by the galvanic nal supply recom- insulation on the I/O units or on the panel unit. mended? An external supply must be used in the following cases: •...
Page 303 5 Electrical connections 5.5.2 24V I/O supply 5.5.2 24V I/O supply General The 24V I/O is not galvanically separated from the rest of the controller voltages. 24 VDC supply for internal and Voltage 24.0 - 26.4V external use Ripple Max. 0.2V Permitted customer load Max.
Page 304 5 Electrical connections 5.5.3 115/230 VAC supply 5.5.3 115/230 VAC supply General This voltage is used in the robot for supplying optional service outlets. The AC supply is not galvanically separated from the rest of the controller voltages. 115/230 VAC sup- ply for internal Voltage 115 VAC or 230 VAC...
Page 305 5 Electrical connections 5.6.1 Connection of the CAN bus Section 5.6: Buses 5.6.1 Connection of the CAN bus Illustration The illustration below shows an example of how to connect the CAN bus: X15 CAN1.1 (Internal I/O) X6 CAN1.2 X7 CAN1.3 X15, X6, X7 1.
Page 306 5 Electrical connections 5.6.1 Connection of the CAN bus If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit on the CAN 1.2 chain. If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3.
Page 307 5 Electrical connections 5.6.1 Connection of the CAN bus The illustration below shows CAN connections on base connector unit: xx0100000243 X6 CAN 1.2 (external I/O) X7 CAN 1.3 (external I/O) X8 CAN 2 (external I/O) X15 CAN 1.1 (internal I/O) 3HAC 16245-1...
Page 308 5 Electrical connections 5.6.2 Interbus-S, slave DSQC 351 5.6.2 Interbus-S, slave DSQC 351 General The unit can be operated as a slave for a Interbus-S system. Supply The Interbus-S slave must be fed externally to avoid shutting down the Interbus-S net if a robot cell is switched off.
Page 309 5 Electrical connections 5.6.2 Interbus-S, slave DSQC 351 Communication The Interbus-S system is able to communicate with a number of external devices, depending concept on the number of process words occupied by each unit. The robot may be equipped with one or two DSQC 351.
Page 310 5 Electrical connections 5.6.2 Interbus-S, slave DSQC 351 Signal name X20 pin Function Not connected TPDO1-N Communication line TPDO1-N TPDI1-N Communication line TPDI1-N Not connected Not connected Connections, The figure below shows the pin configuration of the connector: connector X21, Interbus-S OUT xx0100000220 The table below show the connections to connector X21, Interbus-S OUT:...
Page 311 5 Electrical connections 5.6.2 Interbus-S, slave DSQC 351 Designation Color Description POWER-24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC. NS/MS Green/red See section "CAN bus status LED description". CAN Tx/CAN Rx Green/red See section "CAN bus status LED description".
Page 312 5 Electrical connections 5.6.3 Profibus-DP, slave DSQC 352 5.6.3 Profibus-DP, slave DSQC 352 General The unit can be operated as a slave for a Profibus-DP system. Supply The Profibus does not need any external power feed. All the robot cells are connected to the trunk cable through a special D-sub connector which works as a very short drop cable.
Page 313 5 Electrical connections 5.6.3 Profibus-DP, slave DSQC 352 Master PLC Robot 1, word 1:8 Robot 1, word 9:16 Robot 2, word 17:24 256 inputs/256 outputs 128 inputs/128 outputs Termination The Profibus cable must be terminated in both ends. Connections, X5 See "Device Net Connectors".
Page 314 5 Electrical connections 5.6.3 Profibus-DP, slave DSQC 352 Signal name X3 pin Function Not connected Ground connection Not connected + 24 VDC External supply of Profibus-DP Bus status LEDs The figure and table below show the location and significance of the the LEDs on the board. The designations refer to LEDs shown in the figure in section "Layout, DSQC 352"...
Page 315 5 Electrical connections 5.7.1 Distributed I/O units Section 5.7: I/O units 5.7.1 Distributed I/O units General Up to 20 units can be connected to the same controller but only four of these can be installed inside the controller. Normally a distributed I/O unit is placed outside the controller. Connection The maximum total length of the distributed I/O cable is 100 m (from one end of the chain to the other end).
Page 316 5 Electrical connections 5.7.2 Distributed I/O, digital sensors 5.7.2 Distributed I/O, digital sensors General Digital sensors are connected to one optional digital unit. Technical data See Product Specification for Controller S4Cplus. Allowed types of The table below shows the allowed types of digtal sensors to be used, and their signal levels digital sensors respectively: Sensor type...
Page 317 5 Electrical connections 5.7.3 Distributed I/O, digital I/O DSQC 328 (option) 5.7.3 Distributed I/O, digital I/O DSQC 328 (option) General The digital I/O unit handles digital communication between the robot system and any external systems. Technical data No. of inputs 16 (divided into two groups of 8, galvanically isolated from each other) No.
Page 318 5 Electrical connections 5.7.3 Distributed I/O, digital I/O DSQC 328 (option) Unit function Signal name X1 pin Optically isolated output Out ch 5 Optically isolated output Out ch 6 Optically isolated output Out ch 7 Optically isolated output Out ch 8 Optically isolated output 0 V for outputs 1-8 Optically isolated output...
Page 319 5 Electrical connections 5.7.3 Distributed I/O, digital I/O DSQC 328 (option) Connections, The table below show the connections to connector X4: connector X4 Unit function Signal name X4 pin Optically isolated input In ch 9 Optically isolated input In ch 10 Optically isolated input In ch 11 Optically isolated input...
Page 320 5 Electrical connections 5.7.4 AD Combi I/O, DSQC 327 (optional) 5.7.4 AD Combi I/O, DSQC 327 (optional) General The digital I/O unit handles digital and analog communication between the robot system and any external systems. Technical data No. of digital inputs 16 (divided into two groups of 8, galvanically isolated from each other) No.
Page 321 5 Electrical connections 5.7.4 AD Combi I/O, DSQC 327 (optional) Unit function Signal name X1 pin Optically isolated output Out ch 1 Optically isolated output Out ch 2 Optically isolated output Out ch 3 Optically isolated output Out ch 4 Optically isolated output Out ch 5 Optically isolated output...
Page 322 5 Electrical connections 5.7.4 AD Combi I/O, DSQC 327 (optional) Connections, The table below show the connections to connector X4: connector X4 Unit function Signal name X4 pin Optically isolated input In ch 9 Optically isolated input In ch 10 Optically isolated input In ch 11 Optically isolated input...
Page 323 5 Electrical connections 5.7.5 Analog I/O, DSQC 355 (optional) 5.7.5 Analog I/O, DSQC 355 (optional) General The analog I/O unit handles communication between the robot system and any external sys- tems through analog sensors. Technical data No. of analog inputs 4 (-10 V/+10 V) No.
Page 324 5 Electrical connections 5.7.5 Analog I/O, DSQC 355 (optional) Connections, The figure below shows the pin configuration of the connector: connectors X7 analog output xx0100000236 The table below show the connections to connector X7: Signal name X7 pin Explanation ANOUT_ Analog output 1, -10 V/+10 V ANOUT_ Analog output 2, -10 V/+10 V...
Page 325 5 Electrical connections 5.7.5 Analog I/O, DSQC 355 (optional) Connections, The figure below shows the pin configuration of the connector: connectors X8 analog input xx0100000237 The table below show the connections to connector X8: Signal name X7 pin Explanation ANIN_1 Analog input 1, -10 V/+10 V ANIN_2 Analog input 2, -10 V/+10 V...
Page 326 5 Electrical connections 5.7.5 Analog I/O, DSQC 355 (optional) Signal name X7 pin Explanation The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-oscillation current.
Page 327 5 Electrical connections 5.7.6 Encoder interface unit, DSQC 354 (optional) 5.7.6 Encoder interface unit, DSQC 354 (optional) General The encoder interface unit handles communication with external conveyor: • One encoder input (synchronisation of conveyor position with robot movements). The encoder is supplied with 24 V and 0 V, and sends position information in two channels. This information is computed by the on-board computer using quadrature decoding (QDEC) to determine position and direction.
Page 328 5 Electrical connections 5.7.6 Encoder interface unit, DSQC 354 (optional) Encoder The figure below show the encoder connections: connections 24 VDC Opto Opto 24 VDC Opto Opto Opto Opto xx0100000234 24 V I/O or external supply 0 V I/O or external supply Encoder Sync switch 10-16 not used...
Page 329 5 Electrical connections 5.7.6 Encoder interface unit, DSQC 354 (optional) Signal name X20 pin Explanation Not used Not used Not used Not used The figure below show the layout of the pins in connector X20: xx0100000235 Bus status LEDs The figure and table below show the location and significance of the the LEDs on the board. Designation Color Description...
Page 330 5 Electrical connections 5.7.6 Encoder interface unit, DSQC 354 (optional) Designation Color Description DIGIN1 Green Digital input. Lit when digital input is active. The input is used for external start signal/conveyor synchronisation point. If there is no light, there is an error due to one or more of the following reasons: •...
Page 331 5 Electrical connections 5.8.1 Allen-Bradley, general Section 5.8: Communication 5.8.1 Allen-Bradley, general General The robot may communicate with the Allen Bradley system only, or be used in combination with the I/O system in the robot. For example, the inputs to the robot may come from the Allen Bradley system while the outputs from the robot control external equipment via general I/O addresses and the Allen Bradley system only reads the outputs as status signals.
Page 332 The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor cable. Layout, DSQC The figure below show the layout of the DSQC 350 board: DS QC 350 ABB F lexible Automation xx0100000226 Not used DeviceNet and ID connector RIO in...
Page 333 Allen-Bradley Company, Inc. Allen-Bradley Company, Inc. does not warrant or support this product. All warranty and support services for this product are the responsibility of and provided by ABB Flexible Automation. Bus status LEDs The figure and table below show the location and significance of the the LEDs on the board.
Page 334 5 Electrical connections 5.8.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350 Designation Color Description NAC STATUS Green Steady green indicates RIO link in operation. If there is no light, check network, cables and connections. Also check that PLC is operational. Flashing green indicates that communication is established, but the INIT_COMPLETE bit is not set in NA chip, or config- uration, rack size etc.
Page 335 5 Electrical connections 5.8.3 Communication, serial links 5.8.3 Communication, serial links General T he robot has three serial channels, which can be used by the customer to communicate with printers, terminals, computers, and other equipment (see the figure in "Connections" below). •...
Page 336 5 Electrical connections 5.8.3 Communication, serial links The table below shows the signals from the COM1 (RS232): Signal Description Data carrier Detect Receive Data Transmit Data Data Terminal Ready Signal Ground Data Set Ready Request To Send Clear To Send Ring Indicator Not Connected Connections on...
Page 337 5 Electrical connections 5.8.3 Communication, serial links COM3 Signal name X9 socket RxD (Receive Data) RxD N (Receive data N) DATA (Data Signals in Half Duplex Mode) DATA N (Data Signals in Half Duplex Mode N) DCLK (Data Transmission Clock) DCLK N (Data Transmission Clock N) Connections to The figure below shows the MC/CONSOLE connection behind the service hatch:...
Page 338 5 Electrical connections 5.8.4 Communication, Ethernet 5.8.4 Communication, Ethernet General The robot has two Ethernet channels available: • LAN (connected to the Main computer) • Service (connected to the I/O computer) Connection of The figure below shows an outline diagram of the Ethernet TCP/IP: LAN (Main com- puter) E thernet hub...
Page 339 5 Electrical connections 5.8.4 Communication, Ethernet STATUS xx0100000216 Connection of Used for connection of a laptop to the service outlet on cabinet front (behind service hatch) Service on the controller. (I/O Computer) The figure below shows how to connect a laptop to the service outlet: E thernet xx0100000215 For setup parameters, see User’s Guide - System Parameters, Topic: I/O Signals.
Page 340 5 Electrical connections 5.8.5 External operator’s panel 5.8.5 External operator’s panel General All necessary components are supplied, except for the external enclosure. Dimensions for Install the assembled panel in a housing which satisfies protection class, IP 54, in accordance installation with IEC 144 and IEC 529! The following figure shows the main dimensions of the external operator’s panel: M8 (x4)
Page 341 6 Start-up 6.0.1 Inspection before start-up Chapter 6: Start-up 6.0.1 Inspection before start-up General Perform the following checks before starting up the robot system: Check: 1. The controller mains section is protected with fuses. 2. The electrical connections are correct and correspond to the identification plate on the controller.
Page 342 6 Start-up 6.0.2 Start-up 6.0.2 Start-up General 1. Switch on the mains switch on the cabinet. 2. The robot performs its self-test on both the hardware and software, which takes approximately 1 minute. 3. If the robot is not supplied with the software already installed, install the software as described in section "Robot Controller".
Page 343 7 Installation of controller software 7.0.1 Loading system software Chapter 7: Installation of controller software 7.0.1 Loading system software General The robot system may delivered with or without system software. When the system is not delivered with software, this must be downloaded in one of a number of ways. Software installed If the robot controller is ordered with the software installed on delivery, the controller soft- on delivery...
Page 344 7 Installation of controller software 7.0.1 Loading system software Boot Image The transfer and installation of the controller software to the controller storage memory via Ethernet or floppy disks is executed by a basic program named Boot Image. This basic program must always be in the storage memory. At start-up of the controller, with- out any controller software installed, Boot Image will start and ask the operator for controller software installation instructions.
Page 345 FTP Client On the CD is also included a so called FTP client named Voyager. Please note that this is not an ABB product but a shareware program, which means that it can be installed and used for a limited time, but that it has to be registered for permanent use.
Page 346 Boot Disks to transfer the system to the Controller. Step Action Illustration/Info Make sure RobInstall is installed. If not, install it according to the instructions in section "Installation of the RobotWare on the PC". Click the start button on your PC and select programs/ABB Robot- ics/RobInstall/RobInstall. 3HAC 16245-1...
Page 347 7 Installation of controller software 7.0.3 Installing new Robot Controller Software with RobInstall Step Action Illustration/Info The RobInstall start window will open. xx0100000185 3HAC 16245-1...
Page 348 Enter a name for the new control- ler system. Select a saving loca- tion or use the default directory, normally "Program Files\ABB Robotics\system" (see the figure below, position 1). xx0100000180 Enter the RobotWare key or add from file.
Page 349 7 Installation of controller software 7.0.4 Create a new Robot Controller System Step Action Illustration/info If no external options or parame- ters are to be added or changed, press Finish to create the new controller system. Otherwise press Next to continue to "Addi- tional Keys"...
Page 350 7 Installation of controller software 7.0.4 Create a new Robot Controller System Step Action Illustration/Info Press Add to load manipulator calibration data (see the figure above, position 1). This is the calib.cfg file delivered on the Manipulator Parameter disk (see section "The manipulator parame- ter disk").
Page 351 7 Installation of controller software 7.0.4 Create a new Robot Controller System Step Action Illustration/Info If you want the system to start up in query mode, put a mark in the query mode selection square. For further details of the query mode, see section "Start in Query Mode".
Page 352 7 Installation of controller software 7.0.5 Update the Robot Controller image 7.0.5 Update the Robot Controller image Actions Step Action Illustration/Info To update an existing controller system, press Update , see the figure below. xx0100000189 Select a system in the system list and press OK , see the figure above.
Page 353 7 Installation of controller software 7.0.6 Transfer Robot Controller System using Ethernet connection 7.0.6 Transfer Robot Controller System using Ethernet connection Selecting type of Before a system can be downloaded to a robot controller using the RobInstall tool some prep- set-up arations and set up must be done.
Page 354 7 Installation of controller software 7.0.6 Transfer Robot Controller System using Ethernet connection If using Network Intranet Step Action Illustration/Info connection with fixed IP Make sure that the Network protocol is set for TCP/IP addresses properties. Change the TCP/IP Properties in accordance with the values to be used for IP address, Subnet mask and Gate- way.
Page 355 7 Installation of controller software 7.0.6 Transfer Robot Controller System using Ethernet connection Step Action Illustration/Info Select a target system as in the fig- If a direct connection is used with the patch ure, position 1. cable between the PC and the controller front, then just select the default IP address (192.168.125.1) and "Direct"...
Page 356 7 Installation of controller software 7.0.7 Transfer Robot Controller System using floppy disks 7.0.7 Transfer Robot Controller System using floppy disks Before downloading, make sure: there is at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section "Check Storage Capacity".
Page 357 7 Installation of controller software 7.0.7 Transfer Robot Controller System using floppy disks Step Action Illustration/Info Use the finished floppy disks to boot your system as described in section "Boot Disks". 3HAC 16245-1...
Page 358 7 Installation of controller software 7.0.8 RobInstall preferences 7.0.8 RobInstall preferences Customizing Rob- RobInstall may be customized to suit particular requirements. Install Step Action Illustration/Info To customise RobInstall for new programs and optional products, press Preferences as shown in the figure.
Page 359 8 Robot controller 8.0.1 BootImage Chapter 8: Robot controller 8.0.1 BootImage General The BootImage is a basic program which is used to start up the system from "scratch". Purpose of the This program is already installed in the controller at delivery and is used to: program •...
Page 360 8 Robot controller 8.0.2 Start window 8.0.2 Start window When is it shown? xx0100000168 The start window displays the start menu and will appear in the following cases: • When no controller operating system is installed at power on. • After X-START (see section "X-start").
Page 361 8 Robot controller 8.0.3 Reboot Window 8.0.3 Reboot Window When is it The Reboot window will be displayed if any of the system settings are changed or when shown? Reboot is pressed in the Start window as shown in the figure below:. xx0100000169 Button Function...
Page 362 8 Robot controller 8.0.4 Boot Disk Window 8.0.4 Boot Disk Window When is it The Boot Disk window will be displayed when Boot Disks is pressed in the Start window as shown? shown in the figure in section "Start window". How to create Information on how to create boot disks from RobInstall can be found in section "Create Boot boot disks...
Page 363 8 Robot controller 8.0.5 LAN Settings Window 8.0.5 LAN Settings Window When is it The LAN Settings window will be displayed when LAN Settings is pressed in the Network shown? Settings window as shown in the figure in section "Network Settings". en0100000256 NONE will, after the system is rebooted, remove the IP settings.
Page 364 8 Robot controller 8.0.6 Service Settings Window 8.0.6 Service Settings Window When is it The Service Settings window will be displayed when Service Settings is pressed in the Net- shown? work Settings window as shown in the figure in section "Network Settings". en0100000257 returns to the Start window as shown in the figure in section "Start Win- dow".
Page 365 8 Robot controller 8.0.7 System selection window 8.0.7 System selection window When is it The Select System window will be displayed when Select System is pressed in the Start shown? window as shown in the figure in section "Start Window". xx0100000171 CANCEL returns to the Start window as shown in the figure in section "Start Win-...
Page 366 8 Robot controller 8.0.8 How to perform a Restart 8.0.8 How to perform a Restart General Performing a restart may be done in a number of ways. These are detailed below: Reboot (Warm When executing a Warm start, the system reboots with the current system, e.g. to make new start), apply or changed settings take effect.
Page 367 8 Robot controller 8.0.8 How to perform a Restart Step Action Illustration/Info Select Restart from the File menu. Enter the numbers: 1_5_9 (the fifth function key changes to X-START) Press X-START . The system will reboot and return to the Start window as shown in the figure in section "Start Window".
Page 368 8 Robot controller 8.0.8 How to perform a Restart Step Action Illustration/Info Enter the numbers: 1_3_4_6_7_9 (the fifth function key changes to C-START) Press C-START . 3HAC 16245-1...
Page 369 8 Robot controller 8.0.9 How to Start in Query Mode 8.0.9 How to Start in Query Mode Preconditions for It is possible to set some values, e.g. language, IRB type (within the same model) or options, selecting Query at the first start-up of the system, using a C-Start (see section "C-start"), or later on when Mode start performing an I-Start (see section "I-start") if "Use Query Mode at System Boot"...
Page 370 8 Robot controller 8.0.9 How to Start in Query Mode Step Action Illustration/info Select external axes config. You can find the article number of the DC-link used on the unit inside the controller, then use the table below to find out the configuration ID for that DC-link.
Page 371 RobInstall, a directory "MediaPool" will be found in the directory Program Files\ABB Robotics\, and will also be the current one. However any directory in the structure can be set up as the current media pool in the Preference window (see section "Robinstall Preferences").
Page 372 By default, after installing RobInstall, a directory "system" will be found in Program Files\ABB Robotics\ and will also be the current one. However any directory in the structure can be set up as the current system directory in the Create New System window or Select System window.
Page 373 9 System directory structure 9.0.3 File structure in the robot controller mass storage memory 9.0.3 File structure in the robot controller mass storage memory Files in root The root directory of the mass storage memory is called hd0a. This includes several compo- directory, hd0a nents: File name...
Page 374 9 System directory structure 9.0.4 Preparation of S4Cplus software to be installed 9.0.4 Preparation of S4Cplus software to be installed Illustration Media pool S ys tem pool S ys tem Pack in E xt Option in Created files My s ys tem /3haxbbbb-1.nn /3haxcccc-1.nn key.id...
Page 375 9 System directory structure 9.0.5 Handling mass memory storage capacity 9.0.5 Handling mass memory storage capacity General In some cases it is very important that there is enough free space in the mass storage memory, before attempting to download new system software. How to check its capacity, and if required increase it, is detailed below.
Page 376 9 System directory structure 9.0.5 Handling mass memory storage capacity 3HAC 16245-1...
Page 377 10 Calibration 10.1.1 Types of calibration procedures Chapter 10: Calibration Section 10.1: General 10.1.1 Types of calibration procedures When to calibrate Calibrate the measurement system carefully if any of the resolver values has been changed. This may occur when parts affecting the calibration position have been replaced on the robot.
Page 378 10 Calibration 10.1.2 How to calibrate the robot system 10.1.2 How to calibrate the robot system General This section provides an overview of the procedure required when calibrating the robot sys- tem. Many of the steps in the procedure are detailed in other sections to which references are given.
Page 379 10 Calibration 10.1.2 How to calibrate the robot system Additional infor- In addition to the basic calibration procedure detailed above, a number of calibration related mation actions may be performed: Action Detailed in section: How to update the robot revolution counter without per- Updating the revolution counter on forming a complete calibration page 183...
Page 380 10 Calibration 10.1.3 Calibration, prerequisites 10.1.3 Calibration, prerequisites General The calibration procedure may be described as comparing the direction of two sensors, the reference sensor and the calibration sensor, while running the robot to its calibration position, thus reducing the sensor difference to close to zero. All article numbers of relevant equipment are specified in their instructions respectively.
Page 381 General The calibration pendulum kit contains all required hardware to calibrate all robot models (except IRB 6400R) using the calibration pendulum method. These kits may be rented from ABB at this time, but not purchased. Contents of cali- bration pendulum Contents Art.
Page 382 10 Calibration 10.1.4 Calibration pendulum kit, contents Illustration, turn- May be turned both ways to fit IRB 140, IRB 1400, IRB 2400 and IRB 4400. ing disk adapter xx0200000276 Guide pin, 8 mm Guide pin, 6 mm Screw, M10 Screw, M6 Illustration, Fits IRB 6600 and IRB 7600 adapter turning...
Page 383 10 Calibration 10.2.1 Checking the calibration position Section 10.2: Preliminaries 10.2.1 Checking the calibration position General Check the calibration position before any programming of the robot system can begin. This may be done in one of two ways: • Using the program CALxxxx in the system software (xxxx signifying the robot type; IRB xxxx) •...
Page 384 10 Calibration 10.2.1 Checking the calibration position Using the Jog- ging window on Step Action Illustration the teach pendant Open the Jogging window. xx0100000195 Choose running axis-by-axis. xx0100000196 Manually, run the robot axis to a position where the resolver offset value read, is equal to zero.
Page 385 10 Calibration 10.2.2 Updating the revolution counter 10.2.2 Updating the revolution counter Manually running This section details the first step when updating the revolution counter; manually running the the manipulator manipulator to the calibration position. to the calibration position Step Action Illustration Select axis-by-axis motion mode...
Page 386 10 Calibration 10.2.2 Updating the revolution counter Storing the revo- This section details the second step when updating the revolution counter; storing the revolu- lution counter tion counter setting. setting If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury! Step Action...
Page 387 10 Calibration 10.2.3 Calibration procedure on TPU 10.2.3 Calibration procedure on TPU General This section details how to use the Teach Pendant Unit (TPU) when calibrating the robot using the calibration pendulum method. Procedure Step Action Illustration Press the "Program" button on the TPU. xx0300000009 Select "Special", and then "Call service rou- tine".
Page 388 10 Calibration 10.2.4 Initialization of calibration pendulum 10.2.4 Initialization of calibration pendulum General Whenever calibration pendulum is used for calibrating the robot, the equipment must first be initialized as detailed below. The Levelmeter 2000 is shown for reference below: 0000000 0 0000 °...
Page 389 10 Calibration 10.2.4 Initialization of calibration pendulum Address Step Action Info/Illustration Make sure the sensors have different Detailed in the documentation supplied addresses. Any addresses will do, as long by sensor manufacturer. as they differ from each other. Found in the calibration kit box. Connection of sensors Step...
Page 390 10 Calibration 10.3.1 Calibration sensor mounting positions Section 10.3: Calibration 10.3.1 Calibration sensor mounting positions Introduction This section specifies the mounting positions and directions of all calibration sensors on all robot systems using the Calibration Pendulum method. Additional information on calibration, alternative calibration positions etc, may be found in the Installation Manual.
Page 391 10 Calibration 10.3.1 Calibration sensor mounting positions Axis 1 The illustrations below show the mounting position and direction for the calibration sensor, axis 1: IRB 6600, IRB 7600 xx0200000177 Calibration pendulum NOTE! The pendulum is only fitted in one position at a time! Calibration pendulum attachment screw Locating pin 3HAC 16245-1...
Page 392 10 Calibration 10.3.1 Calibration sensor mounting positions Axis 2 The illustrations below show the mounting position and direction for the calibration sensor, axis 2: IRB 6600, IRB 7600 xx0200000178 Calibration pendulum, axis 2 3HAC 16245-1...
Page 393 10 Calibration 10.3.1 Calibration sensor mounting positions Axis 3 The illustrations below show the mounting position and direction for the calibration sensor, axis 3: IRB 6600, IRB 7600 xx0200000179 Calibration sensor, axis 3 NOTE! The pendulum is only fitted in one position at a time! NOTE! The IRB 7600/2.3/500 version requires a slightly different sensor mounting position than the other versions, the sensor being turned 90°.
Page 394 10 Calibration 10.3.1 Calibration sensor mounting positions Axis 4 The illustrations below show the mounting position and direction for the calibration sensor, axis 4: IRB 6600, IRB 7600 xx0200000179 Calibration sensor, axis 4 NOTE! The pendulum is only fitted in one position at a time! NOTE! The IRB 7600/2.3/500 version requires a slightly different sensor mounting position than the other versions, the sensor being turned 90°.
Page 395 10 Calibration 10.3.1 Calibration sensor mounting positions Axis 5 The illustrations below show the mounting position and direction for the calibration sensor, axis 5: IRB 6600, IRB 7600 xx0200000180 Calibration sensor, axis 5 NOTE! The pendulum is only fitted in one position at a time! Adapter, turning disk Axis 6 The illustrations below show the mounting position and direction for the calibration sensor,...
Page 396 10 Calibration 10.3.2 Calibration scales 10.3.2 Calibration scales Introduction This section specifies the calibration scale positions for all robot models. IRB 6600 The illustration below show the calibration scale positions: xx0200000176 Sync scale, axis 1 Sync scale, axes 2-5 Sync scale, axis 6 IRB 7600 The illustration below show the calibration scale positions: xx0100000198...
Page 397 10 Calibration 10.3.3 Calibration, all axes 10.3.3 Calibration, all axes General This section is valid for all robot models using the calibration pendulum procedure except IRB 6400R. It details how to perform the actual fine calibration of each axis using special calibration equipment.
Page 398 10 Calibration 10.3.3 Calibration, all axes Step Action Illustration Connect the measurement cable from the cal- 0 0 0 0 0 0 0 0 0 0 0 0 ibration sensor to the Levelmeter 2000 unit. ° oo A° o o mRAD mm/m Port/Sensor...
Page 399 10 Calibration 10.3.4 Calibrating axes 3-4, IRB 7600/2.3/500 10.3.4 Calibrating axes 3-4, IRB 7600/2.3/500 General Due to the fact that the upper arm tube is slightly shorter on the version than on others, the calibration sensor position on the upper arm is changed. This applies to calibrating axes 3 and 4 of the IRB 7600/2.3/500 only.
Page 400 10 Calibration 10.4.1 Post calibration procedure Section 10.4: After calibration 10.4.1 Post calibration procedure General Perform the following procedure after calibrating any manipulator axes. The procedure is intended to verify that all calibration positions are correct. Procedure Step Action Illustration Run the calibration home position program Detailed in Checking the calibra- twice.
Page 401 10 Calibration 10.5.1 Alternative calibration position Section 10.5: Alternative calibration 10.5.1 Alternative calibration position General The manipulator may be calibrated in any of three positions. The regular calibration instructions detailed for each axis are intended for calibration position 0, i.e. the normal position. Calibration instructions for positions Right (1) and Left (2) are detailed in Alternative calibrating on page 200.
Page 402 10 Calibration 10.5.2 Alternative calibrating 10.5.2 Alternative calibrating General The manipulator may be calibrated in any of three positions, shown in Alternative calibration position on page 199. Procedure Step Action Illustration Calibrate the robot in position 0 for all axes. Set an alternative calibration position before installation if the final installation makes it impossible to reach the calibration 0 position.
Page 403 10 Calibration 10.5.3 New calibration position, axis 1 10.5.3 New calibration position, axis 1 Procedure Use this instruction to change to a new calibration position for axis 1 during definition of a new calibration position. Step Action Illustration Press the "Miscellaneous" button xx0100000194 Select the System parameters window by pressing ENTER.
Page 404 10 Calibration 10.5.4 New calibration offset, axis 1 10.5.4 New calibration offset, axis 1 Procedure Use this instruction when changing to a new calibration offset for axis 1 during definition of a new calibration position. Step Action Illustration Press the "Miscellaneous" button. xx0100000194 Select the Service window by pressing ENTER.
Page 405 10 Calibration 10.5.5 Retrieving offset values 10.5.5 Retrieving offset values Procedure Use this instruction when retrieving new offset values for axis 1 during definition of a new calibration position. Step Action Illustration Press the "Miscellaneous" button. xx0100000194 Select the System parameters window by pressing ENTER. xx0100000200 Select Motor from the Types menu.
Page 406 10 Calibration 10.5.5 Retrieving offset values 3HAC 16245-1...
Page 407 11 Decommissioning 11.0.1 Balancing device, IRB 7600 and IRB 6600/6650 Chapter 11: Decommissioning 11.0.1 Balancing device, IRB 7600 and IRB 6600/6650 General This information is valid for all versions of IRB 6600/6650 as well as IRB 7600! There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it.
Page 408 11 Decommissioning 11.0.1 Balancing device, IRB 7600 and IRB 6600/6650 Step Action Info/Illustration Open a hole in the side of the housing as Use a cutting torch. shown in the figure. 450-500 mm 450-500 mm 450 mm = IRB 6600 500 mm = IRB 7600 xx0200000082 Cut the coils of the three springs inside...
Page 409 Repair Manual, part 1 Industrial Robot IRB 6600 - 225/2.55 IRB 6600 - 175/2.8 IRB 6600 - 175/2.55 IRB 6650 - 200/2.75 IRB 6650 - 125/3.2 M2000A...
Page 411 Repair Manual, part 1, IRB 6600/6650, M2000A 3HAC 16247-1 Revision A...
Page 412 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re- sponsibility for any errors that may appear in this manual. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.
Page 413 Table of Contents 0.0.1 Overview ..............1 0.0.2 Product Documentation .
Page 414 Table of Contents Section 3.4: Frame and base ............73 3.4.1 Removal of SMB related equipment .
Page 415 Table of Contents 5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1 ........189 5.1.8 Wrist (robot v.
Page 416 Table of Contents 3HAC 16247-1...
Page 417 0.0.1 Overview 0.0.1 Overview About This This information product is a manual containing instructions for repairing the complete robot Manual system, mechanically as well as electrically. Usage This manual should be used during repair work. Who Should Read This manual is intended for: This Manual? •...
Page 418 0.0.1 Overview 3HAC 16247-1...
Page 419 The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during oper- ation. A complete listing of all available software manuals is available from ABB Robotics. 3HAC 16247-1...
Page 420 0.0.2 Product Documentation Hardware option Each hardware option is supplied with its own documentation. Each document set contains manual the types of information specified above: • Installation information • Repair information • Maintenance information In addition, spare part information is supplied for the complete option. 3HAC 16247-1...
Page 421 1 Safety, service 1.0.1 Introduction Chapter 1: Safety, service 1.0.1 Introduction Definitions This chapter details safety information for service personnel i.e. personnel performing instal- lation, repair and maintenance work. Sections The chapter "Safety, service" is divided into the following sections: 1.
Page 422 General Any information given in this information product regarding safety, must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with. 1.1.3 Related information...
Page 423 1 Safety, service 1.2.1 Safety risks related to gripper Section 1.2: Safety risks 1.2.1 Safety risks related to gripper Ensure that a gripper is prevented from dropping a workpiece, if such is used. 1.2.2 Safety risks related to tools/workpieces Safe handling It must be possible to turn off tools, such as milling cutters, etc., safely.
Page 424 Nation/region To prevent injuries and damage during the installation of the robot system, the regulations specific regula- applicable in the country concerned and the instructions of ABB Robotics must be complied tions with. Non-voltage •...
Page 425 1 Safety, service 1.2.6 Risks associated with live electric parts • Units inside the controller, e.g. I/O modules, can be supplied with power from an exter- nal source. • The mains supply/mains switch • The power unit • The power supply unit for the computer system (230 VAC) •...
Page 426 1 Safety, service 1.3.1 Safety fence dimensions Section 1.3: Safety actions 1.3.1 Safety fence dimensions General Fit a safety fence or enclosure around the robot to ensure a safe robot installation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.
Page 427 1 Safety, service 1.3.5 Risk of disabling function "Reduced speed 250 mm/s" 1.3.5 Risk of disabling function "Reduced speed 250 mm/s" Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. 1.3.6 Safe use of the Teach Pendant Unit The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON.
Page 428 1 Safety, service 1.3.7 Work inside the manipulator’s working range 3HAC 16247-1...
Page 429 2 Reference information 2.0.1 Introduction Chapter 2: Reference information 2.0.1 Introduction General This chapter presents generic pieces of information, complementing the more specific infor- mation in the following chapters. 3HAC 16247-1...
Page 430 2 Reference information 2.1.1 Applicable Safety Standards Section 2.1: Reference information 2.1.1 Applicable Safety Standards Standards, gen- The robot is designed in accordance with the requirements of: eral • EN 775 - Robot safety. • EN 292-1 - Basic terminology. •...
Page 431 UNBRAKO UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It fea- screws tures special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
Page 432 2 Reference information 2.1.2 Screw joints Tightening torque Below are tables specifying the torque values for different screw joint types: Screws with slot- ted or cross recess head Tightening torque (Nm) Dimension Class 4.8 "dry" M2.5 0.25 Screws with hexagon socket head, “dry”...
Page 433 All components exceeding 22 kg (50 lbs) are high-lighted in this way. ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is avail- able for each manipulator model.
Page 434 2 Reference information 2.1.4 Standard toolkit 2.1.4 Standard toolkit General All service (repairs, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools required are listed directly in the instructions while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.
Page 435 2 Reference information 2.1.5 Special tools, IRB 6600/6650/7600 2.1.5 Special tools, IRB 6600/6650/7600 General All service (repairs, maintenance and installation) instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 18, and of special tools, listed directly in the instructions and also gathered in the table below.
Page 436 2 Reference information 2.1.5 Special tools, IRB 6600/6650/7600 IRB 66X0/ IRB 7600/ Description Art. no. Hydraulic pump 80Mpa 3HAC 13086-1 Hydraulic pump 80Mpa (Glycerin) 3HAC 13086-2 Levelmeter 2000 kit 6369901-348 Lifting device, base 3HAC 15560-1 Lifting device, manipulator 3HAC 15607-1 Lifting device, upper arm 3HAC 15994-1 Lifting device, upper arm...
Page 437 2 Reference information 2.1.6 Performing a leak-down test 2.1.6 Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equip- ment Equipment, etc.
Page 438 2 Reference information 2.1.7 Lifting equipment and lifting instructions 2.1.7 Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each activity instruction. However, how to use each piece of lifting equipment is not detailed in the activity instruction, but in the instruction delivered with each piece of lifting equipment.
Page 439 3 Repair activities, manipulator 3.0.1 Introduction Chapter 3: Repair activities, manipulator 3.0.1 Introduction Definitions This chapter details all repair activities recommended for the manipulator, including for any external units of the manipulator. It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refit- ting of a certain component on the manipulator.
Page 440 3 Repair activities, manipulator 3.1.1 Removal of cable harness Section 3.1: Complete manipulator 3.1.1 Removal of cable harness Location com- The cable harness is located throughout the manipulator as shown in the figure below. plete cable har- ness xx0200000210 Connector at manipulator base, R1.MP and R1.SMB Connectors at motor 1;...
Page 441 3 Repair activities, manipulator 3.1.1 Removal of cable harness Required equip- ment Equipment, etc. Spare part no. Art. no. Note Circuit Diagram 3HAC 13347-1 Included in Repair Manual, part Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Other tools and proce- These procedures include ref-...
Page 442 3 Repair activities, manipulator 3.1.1 Removal of cable harness Step Action Note/Illustration Open the SMB cover carefully. The cable between the battery and the SMB- unit may stay connected, in order to avoid recalibration of the robot. Be careful not to let the weight of the cover strain the cable! In order to remove the cover completely, the connector R1.G must be disconnected! This...
Page 443 3 Repair activities, manipulator 3.1.1 Removal of cable harness Location of cable The location of the cable harness, axes 5-6, is shown in the figure below. harness ax 5-6 xx0200000213 Cable bracket, wrist unit Cable bracket, upper arm tube Connectors at motor axis 5; R4.FB5 and R4.MP5 Connectors in upper arm tube;...
Page 444 3 Repair activities, manipulator 3.1.1 Removal of cable harness Removal, cable The procedure below details how to remove the upper cable harness. The separate cable that harness, axes 5-6 goes from the connection point inside of the upper arm tube to the motor, axis 5, is not included in this procedure.
Page 445 3 Repair activities, manipulator 3.1.1 Removal of cable harness Step Action Note/Illustration Remove the cable attachment, rear. Shown in the figure Location of cable harness ax 5-6 on page 27! Disconnect connectors R2.M5/6 at the Shown in the figure Location of cable cable harness division point.
Page 446 3 Repair activities, manipulator 3.1.2 Refitting of cable harness 3.1.2 Refitting of cable harness Location of cable The cable harness is located throughout the manipulator as shown in the figure below. harness xx0200000210 Connector at manipulator base, R1.MP and R1.SMB Connectors at motor 1;...
Page 447 3 Repair activities, manipulator 3.1.2 Refitting of cable harness Required equip- ment Equipment, etc. Spare part no. Art. no. Note Cable harness, axes 1-4 3HAC 14940-1 IRB 6600 Cable harness, axes 1-4 3HAC 16331-1 IRB 6650 Cable harness, axes 5-6 3HAC 14140-1 Cable harness, axis 5 3HAC 14139-1...
Page 448 3 Repair activities, manipulator 3.1.2 Refitting of cable harness Step Action Note/Illustration Refit the rear cover plate on the manipulator with its attachment screws. Reconnect all connectors at motor 1 and Specified in the figure Location of motor 2. cable harness on page 30! Secure the gland plate with four attachment MP2 MP1 screws from inside the SMB recess.
Page 449 3 Repair activities, manipulator 3.1.2 Refitting of cable harness Step Action Note/Illustration 15. Reconnect connector R2.M5/6 gently at the Shown in the figure Location of cable rear cable division point. harness on page 30! Be careful not to bend the attachment plate M6, 2 pcs.
Page 450 3 Repair activities, manipulator 3.1.2 Refitting of cable harness Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g.
Page 451 3 Repair activities, manipulator 3.1.2 Refitting of cable harness Step Action Note/Illustration Refit the cover, upper arm and the cover, wrist unit. Make sure the cabling is placed correctly when refitting the covers, and does not get jammed. xx0200000214 • A: cover, wrist unit •...
Page 452 3 Repair activities, manipulator 3.1.3 Removal of complete arm system 3.1.3 Removal of complete arm system Location of arm The complete arm system is defined as the complete manipulator except for the base and system gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in the figure below.
Page 453 3 Repair activities, manipulator 3.1.3 Removal of complete arm system Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Other tools and procedures These procedures include may be required.
Page 454 3 Repair activities, manipulator 3.1.3 Removal of complete arm system Step Action Note/Illustration Fit the lifting device and adjust it as Art. no. specified in Required equipment on detailed in enclosed instruction. page 36! Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting device! Follow the instructions before continu-...
Page 455 3 Repair activities, manipulator 3.1.4 Refitting of complete arm system 3.1.4 Refitting of complete arm system Location of arm The complete arm system is defined as the complete manipulator except for the base and system gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in the figure below.
Page 456 3 Repair activities, manipulator 3.1.4 Refitting of complete arm system Equipment, etc. Spare part no. Art. no. Note Guide pins, M12 x 130 Used to guide the complete arm system when refitting. Always use the guide pins in pairs! Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!
Page 457 3 Repair activities, manipulator 3.1.4 Refitting of complete arm system Step Action Note/Illustration Look through the empty mounting hole of This is a complex task to be performed motor 1 to assist in aligning the assembly with utmost care in order to avoid injury during refitting of the arm system.
Page 458 3 Repair activities, manipulator 3.2.1 Removal of turning disk Section 3.2: Upper arm 3.2.1 Removal of turning disk Location of turn- The turning disk is located in the front of the wrist housing, as shown in the figure below. The ing disk two different robot versions result in different designs of the turning disks.
Page 459 3 Repair activities, manipulator 3.2.1 Removal of turning disk Removal, turning The procedure below details how to remove the turning disk. disk Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 460 3 Repair activities, manipulator 3.2.2 Refitting of turning disk 3.2.2 Refitting of turning disk Location of turn- The turning disk is located in the front of the wrist housing, as shown in the figure below. The ing disk two different robot versions result in different designs of the turning disks. A more detailed view of the component and its position may be found in the Foldout section Wrist complete on page 211.
Page 461 3 Repair activities, manipulator 3.2.2 Refitting of turning disk Required equip- ment Equipment, etc. Spare part no. Art. no. Note Turning disk, dia 200 3HAC 9744-5 For robot version 175/2.55. O-rings are not included! Turning disk, dia 200 3HAC 13752-1 For robot version 225/2.55, 175/ 2.8, 125/3.2 or 200/2.75.
Page 462 3 Repair activities, manipulator 3.2.2 Refitting of turning disk Step Action Note/Illustration Lubricate the turning disk o-ring Art. no. specified in Required equipment on with grease. page 45! Fit the o-ring to the rear of the turn- ing disk. Fit also the 6 or 12 pcs of o-rings (depending on robot version), when refitting the attachment screws.
Page 463 3 Repair activities, manipulator 3.2.3 Removal of complete wrist unit 3.2.3 Removal of complete wrist unit Location of wrist The wrist unit is located in the frontmost part of the upper arm as shown in the figure below. unit A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211.
Page 464 3 Repair activities, manipulator 3.2.3 Removal of complete wrist unit Required equip- ment Equipment etc. Spare part no. Art. no. Note Lifting tool, wrist unit 3HAC 13605-1 Circuit diagram 3HAC 13347-1 Included in Repair Manual, part 2 Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Other tools and proce-...
Page 465 3 Repair activities, manipulator 3.2.3 Removal of complete wrist unit Step Action Note/Illustration Loosen the cable bracket on top of the wrist by Shown in the figure Location of unscrewing the three attachment screws. wrist unit on page 47! Two of the attachment screws are located visi- ble at the rear of the bracket (B) and the third located at the bottom of the cable bracket, in the center (C), shown in the figure to the right.
Page 466 3 Repair activities, manipulator 3.2.4 Refitting of complete wrist unit 3.2.4 Refitting of complete wrist unit Location of wrist The wrist unit is located in the frontmost part of the upper arm as shown in the figure below. unit A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211.
Page 467 3 Repair activities, manipulator 3.2.4 Refitting of complete wrist unit Required equip- ment Equipment etc. Spare part no. Art. no. Note Wrist, 175/2.55 3HAC 16627-1 Includes complete axis 6, 3HAC 9744-1/3HAC 16032-1 (Foundry). Includes rotational motor incl. gearbox, 3HAC 7941-29. Wrist, 225/2.55, 175/2.8, 3HAC 16626-1 Includes complete axis 6,...
Page 468 3 Repair activities, manipulator 3.2.4 Refitting of complete wrist unit Step Action Note/Illustration Lift the wrist unit and guide it to the upper arm tube with help of the guide pins. Make sure the cabling from motor, axis 5 is safely run into the arm tube and doesn´t get into a scrape.
Page 469 3 Repair activities, manipulator 3.2.4 Refitting of complete wrist unit Step Action Note/Illustration 13. Recalibrate the robot! Detailed in "Calibration" in the Installa- tion Manual. 14. Refit any equipment previously removed from the turning disk. When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all the service tools and other foreign objects are removed from the manipulator! - all normal safety equipment is installed properly, e.g.
Page 470 3 Repair activities, manipulator 3.2.5 Removal of upper arm 3.2.5 Removal of upper arm Location of upper The upper arm is located on top of the manipulator as shown in the figure below. The com- plete upper arm includes the wrist unit but this instruction also describes how to remove the upper arm when there is no wrist unit mounted.
Page 471 3 Repair activities, manipulator 3.2.5 Removal of upper arm Attachment hole for lifting eye, M12 Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted) Oil plug, draining, gearbox axis 3 Connectors at cable harness division; R2.M5/6 Motor, axis 3 Motor, axis 4 Attachment screws and washers, upper arm...
Page 472 3 Repair activities, manipulator 3.2.5 Removal of upper arm Step Action Note/Illustration Fit the lifting eye, VLBG M12 to the attachment hole Art. no. specified in Required on the upper arm, if the wrist unit is mounted. equipment on page 55! Shown in the figure Location of upper arm on page 54! Upper arm including wrist unit: Fit one of the...
Page 473 3 Repair activities, manipulator 3.2.6 Refitting of upper arm 3.2.6 Refitting of upper arm Location of upper The upper arm is located on top of the manipulator as shown in the figure below. The com- plete upper arm includes the wrist unit but this instruction also describes how to refit the upper arm when there is no wrist unit mounted.
Page 474 3 Repair activities, manipulator 3.2.6 Refitting of upper arm Attachment hole for lifting eye, M12 Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted) Oil plug, draining, gearbox axis 3 Connectors at cable harness division; R2.M5/6 Motor, axis 3 Motor, axis 4 Attachment screws and washers, upper arm...
Page 475 3 Repair activities, manipulator 3.2.6 Refitting of upper arm Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel! Step Action Note/Illustration...
Page 476 3 Repair activities, manipulator 3.2.6 Refitting of upper arm Step Action Note/Illustration Fasten the lifting tool (chain) onto the lift- Art. no. specified in Required equip- ing eye, the lifting device and an overhead ment on page 58! crane. Lift the upper arm and run to its mounting position.
Page 477 3 Repair activities, manipulator 3.2.6 Refitting of upper arm Step Action Note/Illustration Perform a leakdown test. Detailed in Performing a leak-down test on page 21. Refill the gearbox with oil. Detailed in "Oil change, gearbox axis 3" in the Maintenance Manual. Recalibrate the robot.
Page 478 3 Repair activities, manipulator 3.3.1 Removal of complete lower arm Section 3.3: Lower arm 3.3.1 Removal of complete lower arm Location of lower The lower arm is located as shown in the figure below. A more detailed view of the component and its position may be found in the Foldout section Frame-Lower arm 2 on page 207.
Page 479 3 Repair activities, manipulator 3.3.1 Removal of complete lower arm Attachment The lower arm attachment points are located as shown in the figure below: points, lower arm • The figure (1) shows gearbox axis 3, but the location of sealing axis 2/3 in relation to the gearbox is identical for axis 2.
Page 480 3 Repair activities, manipulator 3.3.1 Removal of complete lower arm Required equip- ment Equipment, etc. Spare part no. Art. no. Note Lifting tool, lower arm 3HAC 14691-1 Tool that may be rent from ATRP/S. Press tool, axis 2 shaft 3HAC 13452-1 Lifting eye, M12 3HAC 14457-3 Used to lift the balancing device.
Page 481 3 Repair activities, manipulator 3.3.1 Removal of complete lower arm Step Action Note/Illustration Apply the lifting eye to the balancing Art. no. specified in Required equipment device and raise to unload the device. on page 64. Attachment shown in the figure Location of lower arm on page 62.
Page 482 3 Repair activities, manipulator 3.3.1 Removal of complete lower arm Step Action Note/Illustration 14. Fit the press (/puller) tool to the shaft as Art. no. specified in Required equipment shown in the figure to the right and on page 64! mount the hydraulic pump to it.
Page 483 3 Repair activities, manipulator 3.3.2 Refitting of complete lower arm 3.3.2 Refitting of complete lower arm Location of lower The lower arm is located as shown in the figure below. A more detailed view of the component and its location may be found in the Foldout section Frame-Lower arm 2 on page 207 xx0200000255 Lower arm...
Page 484 3 Repair activities, manipulator 3.3.2 Refitting of complete lower arm Attachment The lower arm attachment points are located as shown in the figure below: points, lower arm • The figure (1) shows gearbox axis 3, but the location of sealing axis 2/3 in relation to the gearbox is identical for axis 2.
Page 485 3 Repair activities, manipulator 3.3.2 Refitting of complete lower arm Required equip- ment Equipment, etc. Spare part no. Art. no. Note Bearing 3HAC 12441-2 Always use a new bearing when reassembling! Sealing, axis 2/3 3HAC 12443-2 Always use a new sealing when reassembling! VK-cover VK 120 x 12 3HAA 2166-23 Mount on new lower arm or...
Page 486 3 Repair activities, manipulator 3.3.2 Refitting of complete lower arm The lower arm weighs 160 kg! All lifting equipment used must be dimensioned accordingly! Step Action Note/Illustration Fit a new VK-cover on a new lower arm Part no. specified in Required equipment or replace the existing if damaged.
Page 487 3 Repair activities, manipulator 3.3.2 Refitting of complete lower arm Step Action Note/Illustration Remove the guidings and secure the two remaining screws as detailed above! Clean the shaft with isopropanol. Art no. specified in Required equipment on page 69! 10. Apply grease to the shaft hole. Art no.
Page 488 3 Repair activities, manipulator 3.3.2 Refitting of complete lower arm Step Action Note/Illustration 23. Refit and restore the balancing device. Detailed in section Refitting of balancing device on page 85. 24. Refit the upper arm. Detailed in section Refitting of upper arm on page 57.
Page 489 3 Repair activities, manipulator 3.4.1 Removal of SMB related equipment Section 3.4: Frame and base 3.4.1 Removal of SMB related equipment Location of SMB The SMB related equipment (SMB = serial measurement board) is located on the left hand related equip- side of the frame as shown in the figure below.
Page 490 Shown in the figure Location of SMB related equipment on page 73! Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved eqvivalent. Removal, SMB The procedure below details how to remove the SMB unit. unit...
Page 491 SMB Unit 3HAC 13149-1 SMB Battery 3HAC 16831-1 Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved eqviv- alent. Cable, battery/SMB 3HAC 13151-1 board Circuit Diagram 3HAC 13347-1 Included in Repair Manual, part 2...
Page 492 3 Repair activities, manipulator 3.4.2 Refitting of SMB related equipment Refitting, battery The procedure below details how to refit the SMB battery. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 493 3 Repair activities, manipulator 3.4.2 Refitting of SMB related equipment Step Action Note/Illustration If disconnected, reconnect the con- nectors X8, X9 and X10 to the brake release board. Secure the SMB cover with its attach- Shown in the figure Location of SMB ment screws.
Page 494 3 Repair activities, manipulator 3.4.3 Removal of brake release unit 3.4.3 Removal of brake release unit Location of brake The brake release unit is located together with the SMB unit on the left hand side of the frame, release unit right below the gearbox, axis 2, as shown in figure below (IRB 7600 shown).
Page 495 3 Repair activities, manipulator 3.4.3 Removal of brake release unit Removal, brake The procedure below details how to remove the brake release unit. release unit Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 496 3 Repair activities, manipulator 3.4.4 Refitting of brake release unit 3.4.4 Refitting of brake release unit Location of brake The brake release unit is located together with the SMB unit on the left hand side of the frame, release unit right below the gearbox, axis 2, as shown in figure below (IRB 7600 shown).
Page 497 3 Repair activities, manipulator 3.4.4 Refitting of brake release unit Equipment, etc. Spare part no. Art. no. Note Other tools and proce- These procedures include ref- dures may be required. erences to the tools required. See references to these procedures in the step- by-step instructions below.
Page 498 3 Repair activities, manipulator 3.4.5 Removal of balancing device 3.4.5 Removal of balancing device Location of bal- The balancing device is located on rear top of the frame as shown in the figure below. ancing device D, E xx0200000223 Balancing device Hole for lower arm locking screw Attachment hole for lifting eye Rear cover...
Page 499 3 Repair activities, manipulator 3.4.5 Removal of balancing device Equipment, etc Spare part no. Art. no. Note Hydraulic cylinder 3HAC 11731-1 To be used with press tool 3HAC 15767-1. Hydraulic pump 3HAC 13086-1 To be used with hydraulic cylin- der, 3HAC 11731-1. Securing screw 9ADA 183-66 M12 x 35, 2 pcs required.
Page 500 3 Repair activities, manipulator 3.4.5 Removal of balancing device Step Action Note/Illustration Unload the balancing device with the Art. no. specified in Required equip- press tool in order to make the piston rod ment on page 82! and front ear adjustable when pulling the Detailed in Unloading the balancing shaft out.
Page 501 3 Repair activities, manipulator 3.4.6 Refitting of balancing device 3.4.6 Refitting of balancing device Location of bal- The balancing device is located on rear top of the frame as shown in the figure below. ancing device D, E xx0200000223 Balancing device Hole for lower arm locking screw Attachment hole for lifting eye Rear cover...
Page 502 3 Repair activities, manipulator 3.4.6 Refitting of balancing device Equipment Spare part no. Art. no. Note O-ring 3HAB 3772-44 3 pcs, to be replaced if damaged! Locking screw 3HAA 1001-266 M16 x 60. For securing the lower arm. Securing screw 9ADA 183-66 M12 x 35, 2 pcs required.
Page 503 3 Repair activities, manipulator 3.4.6 Refitting of balancing device Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal! The balancing device weighs 210 kg! All lifting equipment used must be dimensioned accord- ingly! Step...
Page 504 3 Repair activities, manipulator 3.4.6 Refitting of balancing device Step Action Note/Illustration Unload the balancing device with the press Detailed in Unloading the balancing tool. device on page 89. Art. no. specified in Required equip- ment on page 85! For an easier reassembling of the shaft, the piston rod may be pressed out more than necessary and then pressed in when fitting the shaft.
Page 505 3 Repair activities, manipulator 3.4.7 Unloading the balancing device 3.4.7 Unloading the balancing device Press tool and This section implies that the lower arm is already secured according to the instruction for the hydraulic cylinder current repair activity, e.g removal of the balancing device. The figure below shows the hydraulic cylinder mounted on the press tool.
Page 506 3 Repair activities, manipulator 3.4.7 Unloading the balancing device Unloading the The procedure below details how to unload the balancing device, using the press tool 3HAC balancing device 15767-1. How to remove the press tool, is detailed in section Restoring the balancing device on page 91.
Page 507 3 Repair activities, manipulator 3.4.8 Restoring the balancing device 3.4.8 Restoring the balancing device Press tool and Restoration is done after repair work that has included the unloading of the balancing device. hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool. xx0200000174 Bolt (4 pcs) Hydraulic cylinder...
Page 508 3 Repair activities, manipulator 3.4.8 Restoring the balancing device Restoring the bal- The procedure below details how to restore the balancing device, i.e. removing the press tool ancing device 3HAC 15767-1. Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal! Step...
Page 509 3 Repair activities, manipulator 3.5.1 Removal of motor, axis 1 Section 3.5: Motors 3.5.1 Removal of motor, axis 1 Location of motor The motor axis 1 is located on the left hand side of the manipulator as shown in the figure below.
Page 510 3 Repair activities, manipulator 3.5.1 Removal of motor, axis 1 Removal The procedure below details how to remove motor, axis 1. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 511 3 Repair activities, manipulator 3.5.2 Refitting of motor, axis 1 3.5.2 Refitting of motor, axis 1 Location of motor The motor axis 1 is located on the left hand side of the manipulator as shown in the figure below. xx0200000200 Motor, axis 1 Motor attachment screws and washers Required equip-...
Page 512 3 Repair activities, manipulator 3.5.2 Refitting of motor, axis 1 Equipment, etc. Spare part no. Art. no. Note Other tools and proce- These procedures include refer- dures may be required. ences to the tools required. See references to these procedures in the step-by-step instructions below.
Page 513 3 Repair activities, manipulator 3.5.3 Removal of motor axis 2 3.5.3 Removal of motor axis 2 Location of motor The motor axis 2 is located on the left hand side of the manipulator as shown in the figure below. xx0200000169 Motor axis 2 Hole for lock screw Cable gland cover (located on the lower side of the motor)
Page 514 3 Repair activities, manipulator 3.5.3 Removal of motor axis 2 Equipment etc. Spare part no. Art. no. Note Circuit diagram 3HAC 13347-1 Included in the Repair Manual, part 2. Standard toolkit 3HAC 15571-1 The contents are defined in sec- tion Standard toolkit on page 18! Other tools and pro- These procedures include refer- cedures may be...
Page 515 3 Repair activities, manipulator 3.5.3 Removal of motor axis 2 Step Action Note/Illustration Fit the two guide pins in the two lower motor Art. no. specified in Required attachment holes. equipment on page 97! Shown in the figure Location of motor on page 97! If required, press the motor out of position by fit- Art.
Page 516 3 Repair activities, manipulator 3.5.4 Refitting of motor axis 2 3.5.4 Refitting of motor axis 2 Location of motor The motor, axis 2, is located on the left hand side of the manipulator as shown in the figure below. xx0200000169 Motor axis 2 Hole for lock screw Cable gland cover (located on the lower side of the motor)
Page 517 3 Repair activities, manipulator 3.5.4 Refitting of motor axis 2 Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, 1.5 A. For releasing the brakes. Rotation tool, motor 3HAC 17105-1 Used to rotate the motor pinion pinion when mating it to the gear, when brakes are released with 24VDC power supply.
Page 518 3 Repair activities, manipulator 3.5.4 Refitting of motor axis 2 Step Action Note/Illustration Remove the lifting tool and allow the motor to rest on the guide pins. Use the rotation tool in order to rotate the Art. no. specified in Required equip- motor pinion when mating it to the gear (see ment on page 100! figure beside).
Page 519 3 Repair activities, manipulator 3.5.5 Removal of motor, axis 3 3.5.5 Removal of motor, axis 3 Location of motor The motor axis 3 is located on the left hand side of the manipulator as shown in the figure below. xx0200000186 Motor, axis 3 Cable gland cover, motor axis 3 Attachment screws and washers (4 pcs)
Page 520 3 Repair activities, manipulator 3.5.5 Removal of motor, axis 3 Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC 15571-1 The contents are defined in sec- tion Standard toolkit on page 18! Other tools and pro- These procedures include refer- cedures may be ences to the tools required.
Page 521 3 Repair activities, manipulator 3.5.5 Removal of motor, axis 3 Step Action Note/Illustration Release the brake by connecting the 24 VDC Connect to connector R2.MP3 power supply. • +: pin 2 Make sure the weight of the complete upper • -: pin 5 arm rests safely on the mechanical stops, the fork lift or the lifting slings before removing the...
Page 522 3 Repair activities, manipulator 3.5.6 Refitting of motor, axis 3 3.5.6 Refitting of motor, axis 3 Location of motor The motor axis 3 is located on the left hand side of the manipulator as shown in the figure below. xx0200000186 Motor axis 3 Cable gland cover, motor axis 3 Motor attachment holes (4 pcs)
Page 523 3 Repair activities, manipulator 3.5.6 Refitting of motor, axis 3 Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, max. 1.5 A. For releasing the brakes. Circuit Diagram 3HAC 13347-1 Included in the Repair Manual, part 2. Standard toolkit 3HAC 15571-1 The contents are defined in sec- tion Standard toolkit on page 18!
Page 524 3 Repair activities, manipulator 3.5.6 Refitting of motor, axis 3 Step Action Note/Illustration Use the rotation tool in order to rotate the Art no. specified in Required equipment motor pinion when mating it to the gear! on page 106! Fit the motor, making sure the motor pin- Make sure the motor pinion does not ion is properly mated to the gear of gear- get damaged!
Page 525 3 Repair activities, manipulator 3.5.7 Removal of motor, axis 4 3.5.7 Removal of motor, axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. xx0200000202 Motor, axis 4 Cable gland cover, motor axis 4...
Page 526 3 Repair activities, manipulator 3.5.7 Removal of motor, axis 4 Removal, motor The procedure below details how to remove motor, axis 4. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 527 3 Repair activities, manipulator 3.5.8 Refitting of motor, axis 4 3.5.8 Refitting of motor, axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. xx0200000202 Motor, axis 4 Cable gland cover, motor axis 4...
Page 528 3 Repair activities, manipulator 3.5.8 Refitting of motor, axis 4 Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC 15571-1 The contents are defined in sec- tion Standard toolkit on page 18! Other tools and pro- These procedures include refer- cedures may be ences to the tools required.
Page 529 3 Repair activities, manipulator 3.5.8 Refitting of motor, axis 4 Step Action Note/Illustration Use the rotation tool in order to rotate the Art. no. specified in Required equip- motor pinion when mating it to the gear! ment on page 111! Fit the motor, making sure the motor pinion Make sure the motor pinion does not is properly mated to the gear, axis 4.
Page 530 3 Repair activities, manipulator 3.5.9 Removal of motor, axis 5 3.5.9 Removal of motor, axis 5 Location of motor The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below. A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211.
Page 531 3 Repair activities, manipulator 3.5.9 Removal of motor, axis 5 Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Other tools and proce- These procedures include dures may be required.
Page 532 3 Repair activities, manipulator 3.5.9 Removal of motor, axis 5 Step Action Note/Illustration If required, press the motor out of position Art. no. specified in Required equipment by fitting removal tool, motor, M10 to the on page 114! motor attachment screw holes. Always use the removal tools in pairs and diagonally! Lift the motor to get the pinion away from...
Page 533 3 Repair activities, manipulator 3.5.10 Refitting of motor, axis 5 3.5.10 Refitting of motor, axis 5 Location of motor The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below. A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211.
Page 534 3 Repair activities, manipulator 3.5.10 Refitting of motor, axis 5 Equipment, etc. Spare part no. Art. no. Note Measuring tool 6896 134-GN Guide pin, M8 x 100 3HAC 15520-1 For guiding the motor. Guide pin, M8 x 150 3HAC 15520-2 For guiding the motor. Power supply 24 VDC, 1.5 A.
Page 535 3 Repair activities, manipulator 3.5.10 Refitting of motor, axis 5 Step Action Note/Illustration Measure the distance between the motor flange and the outer surface of the pinion with the measuring tool. Modify the distance with shims in order to obtain the same distance as measured when dismounting the old motor (+ 0-0,05 mm).
Page 536 3 Repair activities, manipulator 3.5.11 Removal of motor, axis 6 3.5.11 Removal of motor, axis 6 Location of motor The motor axis 6 is located in the center of the wrist unit as shown in the figure below. A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211.
Page 537 3 Repair activities, manipulator 3.5.11 Removal of motor, axis 6 Equipment, etc. Spare part no. Art. no. Note Other tools and proce- These procedures include ref- dures may be required. erences to the tools required. See references to these procedures in the step- by-step instructions below.
Page 538 3 Repair activities, manipulator 3.5.12 Refitting of motor, axis 6 3.5.12 Refitting of motor, axis 6 Location of motor The motor axis 6 is located in the center of the wrist unit as shown in the figure below. A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211.
Page 539 3 Repair activities, manipulator 3.5.12 Refitting of motor, axis 6 Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, 1.5 A. For releasing the brakes. Grease 3HAB 3537-1 For lubricating the o-ring Circuit Diagram 3HAC 13347-1 Included in Repair Manual, part Standard toolkit 3HAC 15571-1 The contents are defined in sec- tion Standard toolkit on page 18!
Page 540 3 Repair activities, manipulator 3.5.12 Refitting of motor, axis 6 When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all the service tools and other foreign objects are removed from the manipulator! - all normal safety equipment is installed properly, e.g.
Page 541 3 Repair activities, manipulator 3.6.1 Removal of gearbox, axis 1 Section 3.6: Gearboxes 3.6.1 Removal of gearbox, axis 1 Location of gear- The axis 1 gearbox is located between the frame and base as shown in the figure below. A more detailed view of the component and its location may be found in the Foldout section Base incl.
Page 542 3 Repair activities, manipulator 3.6.1 Removal of gearbox, axis 1 Equipment, etc. Spare part no. Art. no. Note Other tools and procedures These procedures include may be required. See refer- references to the tools ences to these procedures required. in the step-by-step instruc- tions below.
Page 543 3 Repair activities, manipulator 3.6.1 Removal of gearbox, axis 1 Step Action Note/Illustration Remove the manipulator’s attach- ment screws to unfasten the base from the foundation. Attach the lifting device, base and Art. no. specified in Required equipment on gear 1 and theand lifting tool page 125! (chain) , to the gearbox.
Page 544 3 Repair activities, manipulator 3.6.2 Refitting of gearbox, axis 1 3.6.2 Refitting of gearbox, axis 1 Location of gear- The axis 1 gearbox is located between the frame and base as shown in the figure below. A more detailed view of the component may be found in Foldout section Base incl. Frame on page 203.
Page 545 3 Repair activities, manipulator 3.6.2 Refitting of gearbox, axis 1 Equipment, etc. Spare part no. Art. no. Note Lifting device, base 3HAC 15560-1 and gear 1 Lifting tool (chain) 3HAC 15556-1 Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Other tools may be...
Page 546 3 Repair activities, manipulator 3.6.2 Refitting of gearbox, axis 1 Step Action Note/Illustration Make sure the two o-rings (C, D) on the cir- Art no. specified in Required equip- cumference of the gearbox are seated ment on page 128! properly in their grooves respectively. Lightly lubricate the o-rings with grease .
Page 547 3 Repair activities, manipulator 3.6.2 Refitting of gearbox, axis 1 Step Action Note/Illustration Secure the gearbox and the three washers M16 x 70, 12.9 quality UNBRAKO, with the 18 attachment screws, base to tightening torque: 300 Nm. gearbox (B). Reused screws may be used, provid- ing they are lubricated as detailed in "Screw joints"...
Page 548 3 Repair activities, manipulator 3.6.3 Removal of gearbox axis 2 3.6.3 Removal of gearbox axis 2 Different designs Between the axis 2 motor and gearbox there is a motor attachment which exists in two differ- ent designs. • The early design of the motor attachment is attached directly to the gearbox, with the front gearbox attachment screws.
Page 549 3 Repair activities, manipulator 3.6.3 Removal of gearbox axis 2 Attachment screws, motor attachment Additional cover Motor attachment Required equip- ment Equipment etc. Spare part no. Art. no. Note Fixture, lower arm 3HAC 13659-1 Includes locking screw for securing the lower arm. Locking screw, lower 3HAA 1001-266 M16 x 60.
Page 550 3 Repair activities, manipulator 3.6.3 Removal of gearbox axis 2 Step Action Note/Illustration Remove any equipment fitted to the turning disk. Run the robot to the calibration position. The upper arm can be directed in three different ways, shown in the figure to the right. The lowered position, as in figure A, is rec- ommended as it gives the least load on the tool.
Page 551 3 Repair activities, manipulator 3.6.3 Removal of gearbox axis 2 Step Action Note/Illustration Unload the balancing device shaft by using Art. no. specified in Required equip- press tool, balancing device. ment on page 133! Detailed in section Unloading the bal- ancing device on page 89! Drain the gearbox, axis 2.
Page 552 3 Repair activities, manipulator 3.6.3 Removal of gearbox axis 2 Step Action Note/Illustration 13. If required, apply two M12 screws to the holes (A), shown in the figure to the right, to press it free. xx0200000172 • A: M12 holes for pressing the gearbox out.
Page 553 3 Repair activities, manipulator 3.6.4 Refitting of gearbox axis 2 3.6.4 Refitting of gearbox axis 2 Different designs Between the axis 2 motor and gearbox there is a motor attachment which exists in two differ- ent designs. • The early design of the motor attachment is attached directly to the gearbox, with the front gearbox attachment screws.
Page 554 3 Repair activities, manipulator 3.6.4 Refitting of gearbox axis 2 Attachment screws, motor attachment Additional cover Motor attachment Required equip- ment Equipment Spare part no. Art. no. Note Gear, axis 2 3HAC 10828-12 Includes gearbox 3HAC 10828- 11 and all o-rings! Does not include "Sealing, axis 2/3"! O-ring...
Page 555 3 Repair activities, manipulator 3.6.4 Refitting of gearbox axis 2 The gear box weighs 52 kg! All lifting equipment used must be dimensioned accordingly! Step Action Note/Illustration Make sure the both o-rings (A) are fitted to Art. no. specified in Required equip- the gearbox as shown in the figure to the ment on page 138! right.
Page 556 3 Repair activities, manipulator 3.6.4 Refitting of gearbox axis 2 Step Action Note/Illustration Fit the new sealing, axis 2/3 on the gear- Art. no. specified in Required equip- box, axis 2, and on to the guide pins. ment on page 138! Do not remove the guide pins for the sealing until the rear gearbox attachment screws are secured.
Page 557 3 Repair activities, manipulator 3.6.4 Refitting of gearbox axis 2 Step Action Note/Illustration Insert and secure 31 of the 33 rear gearbox Shown in the figure Location of gear- attachment screws on the inside of the box on page 137! lower arm.
Page 558 3 Repair activities, manipulator 3.6.5 Removal of gearbox, axis 3 3.6.5 Removal of gearbox, axis 3 Location of gear- The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. A more detailed view of the component and its location may be found in the Foldout section Upper arm on page 209.
Page 559 3 Repair activities, manipulator 3.6.5 Removal of gearbox, axis 3 Equipment, etc. Spare part no. Art. no. Note Guide pin, M12 x 200 3HAC 13056-3 For guiding the gearbox. Guides are to be used in pairs. Guide pin, M12 x 250 3HAC 13056-4 For guiding the gearbox.
Page 560 3 Repair activities, manipulator 3.6.5 Removal of gearbox, axis 3 Step Action Note/Illustration Remove the sealing, axis 2/3 between On reassembly a new sealing must be gearbox and lower arm. used! Place the upper arm safely on a work- bench, in a fixture or similar. Remove the gearbox attachment screws.
Page 561 3 Repair activities, manipulator 3.6.6 Refitting of gearbox, axis 3 3.6.6 Refitting of gearbox, axis 3 Location of gear- The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. A more detailed view of the component and its location may be found in the Foldout section Upper arm on page 209.
Page 562 3 Repair activities, manipulator 3.6.6 Refitting of gearbox, axis 3 Equipment, etc. Spare part no. Art. no. Note Grease 3HAB 3537-1 For lubricating the o-rings. Sealing, axis 2/3 3HAC 12443-2 A new sealing must be used on each assembly! Lifting eye, M12 3HAC 14457-3 Guide pin, M12 x 200 3HAC 13056-3 For guiding the gearbox.
Page 563 3 Repair activities, manipulator 3.6.6 Refitting of gearbox, axis 3 Step Action Note/Illustration Make sure the o-rings are fitted to the gear- Art. no. is specified in Required equip- box. Apply grease to the o-rings to make ment on page 145! sure they stick in their grooves during assembly.
Page 564 3 Repair activities, manipulator 3.6.6 Refitting of gearbox, axis 3 When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all the service tools and other foreign objects are removed from the manipulator! - all normal safety equipment is installed properly, e.g.
Page 565 3 Repair activities, manipulator 3.6.7 Removal of gearbox, axis 6 3.6.7 Removal of gearbox, axis 6 Location of gear- The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. The different robot versions result in two different designs of the gearbox. A more detailed view of the component and its location may be found in the Foldout section Wrist complete on page 211.
Page 566 3 Repair activities, manipulator 3.6.7 Removal of gearbox, axis 6 Removal, gear- The procedure below details how to remove gearbox, axis 6. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 567 3 Repair activities, manipulator 3.6.8 Refitting of gearbox, axis 6 3.6.8 Refitting of gearbox, axis 6 Location of gear- The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. The different robot versions result in two different designs of the gearbox. xx0200000219 Gearbox, axis 6 Attachment screws and washers, gearbox for robot version 175/2.55 (8 pcs)
Page 568 3 Repair activities, manipulator 3.6.8 Refitting of gearbox, axis 6 Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Other tools and proce- These procedures include dures may be required.
Page 569 3 Repair activities, manipulator 3.6.8 Refitting of gearbox, axis 6 Step Action Note/Illustration Secure the gearbox with the attach- Shown in figure above! ment screws and washers. 8 pcs or 18 pcs (depending on robot version): M8 x 40, 12.9 quality UNBRAKO, tightening torque: 30 Nm.
Page 570 3 Repair activities, manipulator 3.6.8 Refitting of gearbox, axis 6 3HAC 16247-1...
Page 571 4 Repair activities, controller cabinet 4.0.1 Introduction Chapter 4: Repair activities, controller cabinet 4.0.1 Introduction Definitions This chapter details all repair activities recommended for the controller. It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refit- ting of a certain component in the controller.
Page 572 4 Repair activities, controller cabinet 4.1.1 Replacement of battery unit, controller Section 4.1: Complete controller cabinet 4.1.1 Replacement of battery unit, controller Location of bat- The battery unit is located at the bottom of the controller. tery unit Rectifier xx0200000103 Battery unit Required equip- ment...
Page 573 4 Repair activities, controller cabinet 4.1.1 Replacement of battery unit, controller Step Action Note/Illustration 1. Remove the battery unit by unscrewing its attachment screws (1). Rectifier xx0200000004 2. Pull the battery unit out. 3. Disconnect the three cables from the battery unit.
Page 574 4 Repair activities, controller cabinet 4.1.2 Replacement of I/O and gateway units 4.1.2 Replacement of I/O and gateway units Location of I/O The I/O and gateway units are located as shown in the figure below. and gateway units I/O-4 I/O-3 I/O-1 I/O-2 xx0200000009...
Page 575 4 Repair activities, controller cabinet 4.1.2 Replacement of I/O and gateway units Removal The procedure below details how to remove an I/O or gateway board. Please observe the following before commencing any repair work on the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar.
Page 576 4 Repair activities, controller cabinet 4.1.3 Replacement of bleeder resistor 4.1.3 Replacement of bleeder resistor Location of The bleeder resistor is located behind the air outlet device, as shown in the figure below. bleeder resistor xx0200000007 Bleeder resistor unit Air outlet device Required equip- ment Equipment, etc.
Page 577 4 Repair activities, controller cabinet 4.1.3 Replacement of bleeder resistor Step Action Note/Illustration 2. Disconnect the cable secured on top of the bleeder resistor unit (see position 1 in the figure). xx0200000015 3. Push down and pull out the bleeder resis- tor unit to release the bleeder resistor unit from the enclosure.
Page 578 4 Repair activities, controller cabinet 4.1.4 Putting the computer unit in the service position 4.1.4 Putting the computer unit in the service position Location of com- The computer unit is located as shown in the figure below. puter unit Rectifier xx0200000105 Computer unit Opening...
Page 579 4 Repair activities, controller cabinet 4.1.4 Putting the computer unit in the service position 3. Push the locking device on the front of the computer unit to the right (see position 1 in the figure). 4. Pull the computer unit out of the cabinet until locked in its end position.
Page 580 4 Repair activities, controller cabinet 4.1.4 Putting the computer unit in the service position Closing The procedure below details how to close the computer unit. Please observe the following before commencing any repair work on the manipulator: Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 581 4 Repair activities, controller cabinet 4.1.5 Replacement of mass storage memory 4.1.5 Replacement of mass storage memory Location of mass The mass storage memory is located in the computer system, which is shown in the figure storage memory below. Rectifier xx0200000105 Computer system Required equip-...
Page 582 4 Repair activities, controller cabinet 4.1.5 Replacement of mass storage memory Step Action Note/Illustration 2. Open the cover on the right side of the com- puter system by unsnapping the two snaps (item 1 in the figure). xx0200000019 3. Disconnect the connectors X1 and X2 from the front of the mass storage memory (items 2 and 3 in the figure).
Page 583 4 Repair activities, controller cabinet 4.1.5 Replacement of mass storage memory Step Action Note/Illustration 3. Close the cover on the right side of the com- puter unit and secure it with the snaps (item 1 in the figure). 4. Put the computer system back in regular Detailed in section "Putting the com- operation position.
Page 584 4 Repair activities, controller cabinet 4.1.6 Replacement of internal cooling fan 4.1.6 Replacement of internal cooling fan Location of inter- The internal cooling fan is located in the computer system, which is shown in the figure nal cooling fan below. xx0200000105 Computer system Required equip-...
Page 585 4 Repair activities, controller cabinet 4.1.6 Replacement of internal cooling fan Step Action Note/Illustration 2. Disconnect the connector E5 or E6 respec- tively, depending on which fan is to be replaced. xx0200000020 • A: Upper fan • B: Lower fan •...
Page 586 4 Repair activities, controller cabinet 4.1.6 Replacement of internal cooling fan Step Action Note/Illustration 1. Tip the internal cooling fan with its top towards the cabi- net wall and fit it into the hole (see the figure). Art. no. specified above! xx0200000021 •...
Page 587 4 Repair activities, controller cabinet 4.1.7 Replacement of drive units and rectifier 4.1.7 Replacement of drive units and rectifier Location of drive The drive units and rectifier are located as shown in the figure below. units and rectifier xx0200000007 Rectifier (drive unit) Drive units Power supply unit Required equip-...
Page 588 4 Repair activities, controller cabinet 4.1.7 Replacement of drive units and rectifier Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar.
Page 589 4 Repair activities, controller cabinet 4.1.7 Replacement of drive units and rectifier Step Action Note/Illustration 1. Fit the unit into position and secure it with the spring. Also see figure above! 2. Refit the power bar in front of the unit. 3.
Page 590 4 Repair activities, controller cabinet 4.1.8 Replacement of system fan unit 4.1.8 Replacement of system fan unit Location of sys- The system fan unit is located under the bleeder resistor uni t, in the back of the controller as tem fan unit shown in the figure below.
Page 591 4 Repair activities, controller cabinet 4.1.8 Replacement of system fan unit Step Action Note/Illustration 3. Disconnect the cable (see position 1 in the figure). Rectifier xx0200000008 4. Pull the back of the system fan unit upwards to free it and then tip it out of the enclosure (see position 2 in the fig- ure).
Page 592 4 Repair activities, controller cabinet 4.1.9 Replacement of power supply unit 4.1.9 Replacement of power supply unit Location of power The power supply unit is located as shown in the figure below. supply unit xx0200000011 Power supply unit Power supply unit locking spring Required equip- ment Equipment, etc.
Page 593 4 Repair activities, controller cabinet 4.1.9 Replacement of power supply unit Step Action Note/Illustration 4. Lift the unit straight up to release it from the hooks in the back and remove it outwards. Refitting The procedure below details how to refit the power supply unit. Please observe the following before commencing any repair work on the controller: Turn off all electric power supply to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will...
Page 594 4 Repair activities, controller cabinet 4.1.10 Replacement of Peltier Cooler power supply 4.1.10 Replacement of Peltier Cooler power supply Location of power The Peltier cooler power supply unit is located as shown in the figure below. supply unit Cover M5 screw Extended Power supply Required equip- ment...
Page 595 4 Repair activities, controller cabinet 4.1.10 Replacement of Peltier Cooler power supply Step Action Note/Illustration 4. Remove the Power supply from the mounting See pos. 3 in previous illustration. rail. Refitting The procedure below details how to refit the power supply unit. Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will...
Page 596 4 Repair activities, controller cabinet 4.1.10 Replacement of Peltier Cooler power supply 3HAC 16247-1...
Page 597 5 Appendix 1: Part Lists 5.0.1 Introduction Chapter 5: Appendix 1: Part Lists 5.0.1 Introduction This chapter is an appendix to the manual and contains part lists with item numbers, refering to the Appendix 2: Foldouts. The part list for the manipulator sometimes differ for robot versions 225/2.25- 175/2.8 and 175.2.25.
Page 598 5 Appendix 1: Part Lists 5.0.1 Introduction Section 5.1: Part List, Manipulator IRB 6600/6650 Item Qty Art. number Description Dimension/Note 3HAC 12812-2 Mechanical stop ax 1, See Mechanical stop ax 1, assembly 3HAC 12812-2 on page 183. 3HAC 12685-1 Base incl frame ax 1 See “Base incl frame ax 1, 3HAC 12685-1”...
Page 599 5 Appendix 1: Part Lists 5.1.1 Mechanical stop ax 1, 3HAC 12812-2 Item Qty Art. number Description Dimension/Note 3HAC 13264-1 Material set ax 1-2 See “Mtrl.set ax 1-2, 3HAC 13264-1” on page 195. 3HAC 13265-1 Mtrl.set balancing device See “Mtrl set balancing device, 3HAC 13265-1”...
Page 600 5 Appendix 1: Part Lists 5.1.3 Axis 3-4, (robot v. 175/2.55), 3HAC 10746-3 Item Art. number Description Dimension 101.1.3 1 3HAC 1383-2 Protection Cover compl. 101.1.4 1 3HAC 14024-1 Protection screw Frame incl ax 1 gearbox, 3HAC 12684-1 Item Art. number Description Dimension 101.2.1 1...
Page 601 5 Appendix 1: Part Lists 5.1.5 Axis 3-4, Foundry (robot v. 175/2.55), 3HAC 10746-5 5.1.5 Axis 3-4, Foundry (robot v. 175/2.55), 3HAC 10746-5 Item Qty Art. number Description Note 102.1 1 3HAC 13350-1 Material set ax 4 See Material set ax 4, 3HAC 13350-1 on page 185! 102.2 1 3HAC 15859-1...
Page 602 5 Appendix 1: Part Lists 5.1.6 Axis 3-4, Foundry (robot v. 225/2.25, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-4 Item Art. number Description Dimension/Note 102.1.14 1 3HAC 11925-1 Mechanical stop head 102.1.15 2 3HAB 3409-81 Hex socket head cap screw M16x35 102.1.16 1 3HAA 1001-98 Gasket 102.1.17 1 3HAC 12149-4 Cover ax4 with sealing...
Page 603 5 Appendix 1: Part Lists 5.1.6 Axis 3-4, Foundry (robot v. 225/2.25, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-4 Damper axis 4, 3HAC 13564-1 Item Qty Art. number Description Dimension 102.1.12.2 3HAC 13564-2 Plate for damper Cover axis 4 with sealing, 3HAC 12149-4 Item Qty Art.
Page 604 5 Appendix 1: Part Lists 5.1.6 Axis 3-4, Foundry (robot v. 225/2.25, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-4 Item Art. number Description Dimension/Note 102.3.6 3HAB 3409-50 Hex socket head cap M10x40 screw 102.3.7 3HAB 4233-1 Washer 102.3.8 3HAC 16721-1 Magnetic plug R 1/2”...
Page 605 5 Appendix 1: Part Lists 5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1 Rot ac motor incl gearbox, 3HAC 14752-1 Item Art. number Description Dimension 102.4.1 1 3HAC 14673-10 Rotational ac motor M10 102.4.2 1 3HAC 12260-1 Pinion Z1 /4 102.4.3 0 2152 2012-430 O-ring 89,5x3...
Page 606 5 Appendix 1: Part Lists 5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5 Item Art. number Description Dimension/Note 103.3 3HAB 3409-89 Hex socket head cap screw M16x80 103.4 3HAC 16032-1 Axis 6 complete Foundry See Axis 6 complete, 3HAC 9744-1/16032-1 on page 192! 103.5...
Page 607 5 Appendix 1: Part Lists 5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5 Item Art. number Description Dimension/Note 103.1.19 3HAC 16721-1 Magnetic plug R 1/2 103.1.21 9ADA 618-56 Torx pan head screw M6x16 103.1.22 9ADA 334-6 Plain washer 6,4x14x1,5 103.1.23 3HAB 7116-1...
Page 608 5 Appendix 1: Part Lists 5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5 Item Art. number Description Dimension 103.1.26.3.2 1 3HAC 7941-5 Gear z4/5 225kg Gear wheel unit z6/5 225, 3HAC 7941-21 Item Art. number Description Dimension 103.1.28.1 1 3HAC 7941-8 Gear z6/5 225kg...
Page 609 5 Appendix 1: Part Lists 5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5 Item Art. number Description Dimension/Note 103.4.5 9ADA 312-7 Plain washer 8,4x16x1,6 103.4.6 9ADA 183-37 Hex socket head cap screw M8x25 103.4.7 3HAA 1001-172 Washer 8,4x13x1,5 103.4.8 2522 122-1...
Page 610 5 Appendix 1: Part Lists 5.1.11 Material set manipulator, 3HAC 13263-1 Item Art. number Description Dimension/Note 103.4.5 9ADA 312-7 Plain washer 8,4x16x1,6 103.4.6 9ADA 183-37 Hex socket head cap screw M8x25 103.4.7 3HAA 1001-172 Washer 8,4x13x1,5 103.4.8 2522 122-1 Magnetic plug R1/4”...
Page 611 5 Appendix 1: Part Lists 5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1 Item Art. number Description Dimension/Note 108.204 33 3HAA 1001-134 Washer 13x19x1,5 108.206 12 3HAB 7700-69 Hex socket head cap screw M12x50 108.207 12 3HAA 1001-134 Washer 13x19x1,5 108.210 1 3HAC 14300-1 Cable protector 108.212 1...
Page 612 5 Appendix 1: Part Lists 5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1 Item Art. number Description Dimension/Note 109.311 1 3HAC 14131-1 Connection plate, base t=3 mm 109.312 1 3HAC 11774-3 Adapter, complete See Adapter, compl., 3HAC 11774-3 on page 197! 109.313 1 3HAC 11769-1 Cable guide, ax.1 109.314 1...
Page 613 5 Appendix 1: Part Lists 5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1 RV 410F-270,176 assembly, 3HAC 17271-1 Item Qty Art. number Description Dimension 109.301.1 1 3HAC 10828-11 RV 410F, i=270,176 109.301.2 2 3HAB 3772-68 O-ring 276x3,53 Rot ac motor incl pinion, 3HAC 14749-1 Item Qty Art.
Page 614 5 Appendix 1: Part Lists 5.1.13 Mtrl set balancing device, 3HAC 13265-1 Protection screw, 3HAC 14024-1 Item Art. number Description Dimension 109.322.1 1 3HAC 13582-1 Protection Screw 109.322.2 1 3HAB 3772-32 O-ring 17x3 Cover SMB and BRU, 3HAC 14692-3 Item Art.
Page 615 5 Appendix 1: Part Lists 5.1.14 Arm extension set, 250 mm, 3HAC 12311-4 5.1.14 Arm extension set, 250 mm, 3HAC 12311-4 Item Art. number Description Dimension 111.501 1 3HAC 9760-3 Arm extender 250mm 111.501 1 3HAC 15859-2 Arm extender 250mm, Foundry 111.503 12 3HAB 7700-69...
Page 616 5 Appendix 1: Part Lists 5.1.15 Arm extension set, 450 mm, 3HAC 12311-5 3HAC 16247-1...
Page 617 6 Appendix 2: Foldouts 6.0.1 Introduction Chapter 6: Appendix 2: Foldouts 6.0.1 Introduction Definitions This chapter is an appendix to the manual and contains detailed views of the components on the manipulator. The numbered details are specified with item numbers in the Appendix 1: Part List. The foldouts are divided into: •...
Page 618 6 Appendix 2: Foldouts 6.0.1 Introduction 3HAC 16247-1...
Page 619 6 Appendix 2: Foldouts 6.0.2 Base incl. Frame 6.0.2 Base incl. Frame 101.2.1 101.2.2 101.5 101.1 101.9 101.6 101.8 101.7 101.2.4 101.2.3 101.3 101.4 xx0200000329 3HAC 16247-1...
Page 620 6 Appendix 2: Foldouts 6.0.2 Base incl. Frame 3HAC 16247-1...
Page 621 6 Appendix 2: Foldouts 6.0.3 Frame-Lower arm 1 6.0.3 Frame-Lower arm 1 xx0200000334 3HAC 16247-1...
Page 622 6 Appendix 2: Foldouts 6.0.3 Frame-Lower arm 1 3HAC 16247-1...
Page 623 6 Appendix 2: Foldouts 6.0.4 Frame-Lower arm 2 6.0.4 Frame-Lower arm 2 108.201, 108.204 110.410 108.202 110.414 110.415 xx0200000335 3HAC 16247-1...
Page 624 6 Appendix 2: Foldouts 6.0.4 Frame-Lower arm 2 3HAC 16247-1...
Page 625 6 Appendix 2: Foldouts 6.0.5 Upper arm 6.0.5 Upper arm xx0200000337 3HAC 16247-1...
Page 626 6 Appendix 2: Foldouts 6.0.5 Upper arm 3HAC 16247-1...
Page 627 6 Appendix 2: Foldouts 6.0.6 Wrist complete 6.0.6 Wrist complete xx0200000336 3HAC 16247-1...
Page 628 6 Appendix 2: Foldouts 6.0.6 Wrist complete 3HAC 16247-1...
Page 629 Maintenance Manual Industrial Robot IRB 6600 - 225/2.55 IRB 6600 - 175/2.8 IRB 6600 - 175/2.55 IRB 6650 - 200/2.75 IRB 6650 - 125/3.2 M2000A...
Page 631 Maintenance Manual, IRB 6600/6650, M2000A 3HAC 16246-1 Revision A...
Page 632 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re- sponsibility for any errors that may appear in this manual. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.
Page 633 Table of Contents 0.0.1 Overview ..............1 0.0.2 Product Documentation .
Page 634: Table Of Contents
Table of Contents Chapter 5: Maintenance activities, manipulator 5.0.1 Introduction ............. . . 43 Section 5.1: Inspection activities .
Page 635 0.0.1 Overview 0.0.1 Overview About This This information product is a manual containing instructions for maintenance of the complete Manual robot system, mechanically as well as electrically. Usage This manual should be used during maintenance work. Who Should Read This manual is intended for: This Manual? •...
Page 636 0.0.1 Overview 3HAC 16246-1...
Page 637 The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during oper- ation. A complete listing of all available software manuals is available from ABB Robotics. 3HAC 16246-1...
Page 638 0.0.2 Product Documentation Hardware option Each hardware option is supplied with its own documentation. Each document set contains manual the types of information specified above: • Installation information • Repair information • Maintenance information In addition, spare part information is supplied for the complete option. 3HAC 16246-1...
Page 639 1 Safety, service 1.0.1 Introduction Chapter 1: Safety, service 1.0.1 Introduction Definitions This chapter details safety information for service personnel i.e. personnel performing instal- lation, repair and maintenance work. Sections The chapter "Safety, service" is divided into the following sections: 1.
Page 640 General Any information given in this information product regarding safety, must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with. 1.1.3 Related information...
Page 641 1 Safety, service 1.2.1 Safety risks related to gripper Section 1.2: Safety risks 1.2.1 Safety risks related to gripper Ensure that a gripper is prevented from dropping a workpiece, if such is used. 1.2.2 Safety risks related to tools/workpieces Safe handling It must be possible to turn off tools, such as milling cutters, etc., safely.
Page 642 Nation/region To prevent injuries and damage during the installation of the robot system, the regulations specific regula- applicable in the country concerned and the instructions of ABB Robotics must be complied tions with. Non-voltage •...
Page 643 1 Safety, service 1.2.6 Risks associated with live electric parts • Units inside the controller, e.g. I/O modules, can be supplied with power from an exter- nal source. • The mains supply/mains switch • The power unit • The power supply unit for the computer system (230 VAC) •...
Page 644 1 Safety, service 1.3.1 Safety fence dimensions Section 1.3: Safety actions 1.3.1 Safety fence dimensions General Fit a safety fence or enclosure around the robot to ensure a safe robot installation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.
Page 645 1 Safety, service 1.3.5 Risk of disabling function "Reduced speed 250 mm/s" 1.3.5 Risk of disabling function "Reduced speed 250 mm/s" Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. 1.3.6 Safe use of the Teach Pendant Unit The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON.
Page 646 1 Safety, service 1.3.7 Work inside the manipulator’s working range 3HAC 16246-1...
Page 647 2 Reference information 2.0.1 Introduction Chapter 2: Reference information 2.0.1 Introduction General This chapter presents generic pieces of information, complementing the more specific infor- mation in the following chapters. 3HAC 16246-1...
Page 648 2 Reference information 2.1.1 Applicable Safety Standards Section 2.1: Reference information 2.1.1 Applicable Safety Standards Standards, The robot is designed in accordance with the requirements of: general • EN 775 - Robot safety. • EN 292-1 - Basic terminology. • EN 292-2 - Technical principles.
Page 649 UNBRAKO UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It fea- screws tures special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
Page 650 2 Reference information 2.1.2 Screw joints Screws with slotted or cross Tightening torque (Nm) recess head Dimension Class 4.8 "dry" M2.5 0.25 Screws with hexagon socket head, “dry” Tightening torque Tightening torque Tightening torque Dimension (Nm) (Nm) (Nm) Class 8.8 "dry" Class 10.9 "dry"...
Page 651 All components exceeding 22 kg (50 lbs) are high-lighted in this way. ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is avail- able for each manipulator model.
Page 652 2 Reference information 2.1.4 Standard toolkit 2.1.4 Standard toolkit General All service (repairs, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools required are listed directly in the instructions while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.
Page 653 2 Reference information 2.1.5 Special tools, IRB 6600/6650/7600 2.1.5 Special tools, IRB 6600/6650/7600 General All service (repairs, maintenance and installation) instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 18, and of special tools, listed directly in the instructions and also gathered in the table below.
Page 654 2 Reference information 2.1.5 Special tools, IRB 6600/6650/7600 IRB 66X0/ IRB 7600/ Description Art. no. Hydraulic pump 80Mpa 3HAC 13086-1 Hydraulic pump 80Mpa (Glycerin) 3HAC 13086-2 Levelmeter 2000 kit 6369901-348 Lifting device, base 3HAC 15560-1 Lifting device, manipulator 3HAC 15607-1 Lifting device, upper arm 3HAC 15994-1 Lifting device, upper arm...
Page 655 2 Reference information 2.1.6 Performing a leak-down test 2.1.6 Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equip- ment Equipment, etc.
Page 656 2 Reference information 2.1.7 Lifting equipment and lifting instructions 2.1.7 Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each activity instruction. However, how to use each piece of lifting equipment is not detailed in the activity instruction, but in the instruction delivered with each piece of lifting equipment.
Page 657 Defining the SIS input duction environment. parameters on page 30. Maintenance intervals recommended by ABB are specified in section "Mainte- nance Schedule" in the Maintenance Manual. Enter these parameters in the system. How to do this is detailed in Setting the SIS parameters on page 33.
Page 658 3 Service Information System (SIS) 3.0.2 Service Information System (SIS) 3.0.2 Service Information System (SIS) General Service Information System (SIS) is a software function within the robot controller, which simplifies maintenance of the robot system. It supervises the operating time and mode of the robot, and alerts the operator when a maintenance activity is scheduled.
Page 659 3 Service Information System (SIS) 3.0.2 Service Information System (SIS) Calendar time This is a clock within the control system that enables you to set a specific service interval, based on calendar time: xx0200000035 After this time, a message is accessible on the Tech Pendant Unit (TPU). How to access this is detailed in section Reading the SIS output logs on page 35.
Page 660 3 Service Information System (SIS) 3.0.2 Service Information System (SIS) Gearbox Based on measurements, torque and RPM, for example, the system calculates an expected service interval for each gearbox. When service is due, a message will be shown on the TPU. How to access this is detailed in section Reading the SIS output logs on page 35.
Page 661 3 Service Information System (SIS) 3.0.2 Service Information System (SIS) Reset values All counters may be reset at any time. en0200000040 When resetting, both variables are reset! sisRestartDate sisCalendarT The variables are described in section Exporting the SIS data on page 36! Resets the counter to zero.
Page 662 3 Service Information System (SIS) 3.0.2 Service Information System (SIS) en0200000039 When resetting, both variables are reset! sisL10h_x sisL10h_Time_x The variables are described in section Exporting the SIS data on page 36! Resets the counter to zero. Does not reset the counter, but returns to the previous menu. Service interval When the service time has been exceeded for the selection made, a message (Service interval exceeded...
Page 663 3 Service Information System (SIS) 3.0.2 Service Information System (SIS) No data available When no data is available for the selection made, a message (No data available!) is displayed below the function in question: en0200000043 This window may be shown for any time mode; calendar time, operation time or gearbox time.
Page 664 Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. The figure below shows the options of parameters to be set.
Page 665 3 Service Information System (SIS) 3.0.3 Defining the SIS input parameters Operation time A percentage of the "Operation time limit" specified above. warning E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an operation time "Reset"...
Page 666 3 Service Information System (SIS) 3.0.3 Defining the SIS input parameters Gearbox warning A percentage of the gearbox service interval as calculated by the system. E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service interval of each gearbox.
Page 667 3 Service Information System (SIS) 3.0.4 Setting the SIS parameters 3.0.4 Setting the SIS parameters General If the SIS system is to function properly, a number of parameters must be set. How to do this is detailed below. Procedure This is an instruction of how to enter SIS parameters to the robot system. Step Action Rem.
Page 668 3 Service Information System (SIS) 3.0.4 Setting the SIS parameters Step Action Rem. Select the required system The parameter list is displayed. en0200000048 en0200000049 Select the required parameters by step- Available parameters are described in ping up and down through the parame- Defining the SIS input parameters on page ter list.
Page 669 3 Service Information System (SIS) 3.0.5 Reading the SIS output logs 3.0.5 Reading the SIS output logs General Whenever a set condition has expired (e.g. max allowed operation time before service), a message to this effect will be shown in the Operational log. Access to logs How to open any log and show its contents is detailed in the "User’s Guide", chapter "Ser- vice".
Page 670 3 Service Information System (SIS) 3.0.6 Exporting the SIS data 3.0.6 Exporting the SIS data General This section describes the available variables for entering SIS parameters as well as showing any messages of exceeded time limits as detected by the SIS counters on an external PC using "Webware SDK".
Page 671 4 Maintenance schedules and intervals 4.0.1 Specification of maintenance intervals Chapter 4: Maintenance schedules and intervals 4.0.1 Specification of maintenance intervals Description The intervals may be specified in different ways depending on the type of maintenance activ- ity to be carried out and the working conditions of the robot: •...
Page 672 4 Maintenance schedules and intervals 4.0.2 Maintenance schedule, IRB 6600/6650 4.0.2 Maintenance schedule, IRB 6600/6650 General The robot, consisting of manipulator and controller cabinet, must be maintained regularly to ensure its function. The maintenance activities and their respective intervals are specified in the table below.
Page 673 4 Maintenance schedules and intervals 4.0.2 Maintenance schedule, IRB 6600/6650 Maintenance Equipment Interval Note Detailed in section activity Changing Axis 6 gear, oil 48 mths Ambient tempera- "Oil change, gearbox ture below 50 °C axis 6" Replacement Axis 1 gear, oil As speci- "Remove/Refit, gear- fied by the...
Page 674 4 Maintenance schedules and intervals 4.0.2 Maintenance schedule, IRB 6600/6650 Maintenance Detailed in Equipment Interval Note activity section Inspection UL-lamp "Inspection, UL- lamp" Inspection Mechanical stop 12 mths Mechanical stops in "Inspection, axes 1-3 addition to the fixed mechanical stop, stops axes 1-3"...
Page 675 4 Maintenance schedules and intervals 4.0.3 Expected component life, IRB 6600 4.0.3 Expected component life, IRB 6600 General The expected life of a component can vary greatly depending on how hard it is run Expected life Component Expected life Note Manipulator harness 2,000,000 cycles See note 1)
Page 676 4 Maintenance schedules and intervals 4.0.4 Maintenance schedule, controller S4CPlus M2000A 4.0.4 Maintenance schedule, controller S4CPlus M2000A General The robot controller must be maintained at regular intervals to ensure its function. The main- tenance activities and their respective intervals are specified in the table below: Intervals Maintenance Equipment...
Page 677: Introduction
5 Maintenance activities, manipulator 5.0.1 Introduction Chapter 5: Maintenance activities, manipulator 5.0.1 Introduction General This chapter contains information on how to maintain the equipment in question, i.e. how to perform the preventive maintenance activities specified in the maintenance schedule for the same equipment.
Page 678: Section 5.1: Inspection Activities
5 Maintenance activities, manipulator 5.1.1 Inspection, oil level gearbox axis 1 Section 5.1: Inspection activities 5.1.1 Inspection, oil level gearbox axis 1 Location of gear- The axis 1 gearbox is located between the frame and base as shown in the figure below. xx0200000228 Gearbox axis 1 Oil plug, inspection...
Page 679 5 Maintenance activities, manipulator 5.1.1 Inspection, oil level gearbox axis 1 Inspection, oil The procedure below details how to inspect the oil level in gearbox axis 1. level gearbox Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Page 680: Inspection, Oil Level Gearbox Axis 2
5 Maintenance activities, manipulator 5.1.2 Inspection, oil level gearbox axis 2 5.1.2 Inspection, oil level gearbox axis 2 Different designs Between the axis 2 motor and gearbox there is a motor attachment which exists in two differ- ent designs. • The early design of the motor attachment is attached directly to the gearbox, with the front gearbox attachment screws.
Page 681 5 Maintenance activities, manipulator 5.1.2 Inspection, oil level gearbox axis 2 Equipment etc. Spare part no. Art. no. Note Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Other tools and proce- These procedures include ref- dures may be required.
Page 682: Inspection, Oil Level Gearbox Axis 3
5 Maintenance activities, manipulator 5.1.3 Inspection, oil level gearbox axis 3 5.1.3 Inspection, oil level gearbox axis 3 Location of gear- The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining...
Page 683 5 Maintenance activities, manipulator 5.1.3 Inspection, oil level gearbox axis 3 Inspection, oil The procedure below details how to inspect the oil level in the gearbox axis 3. level gearbox 3 Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Page 684: Inspection, Oil Level Gearbox Axis 4
5 Maintenance activities, manipulator 5.1.4 Inspection, oil level gearbox axis 4 5.1.4 Inspection, oil level gearbox axis 4 Location of gear- The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below.
Page 685 5 Maintenance activities, manipulator 5.1.4 Inspection, oil level gearbox axis 4 - Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2. When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Page 686: Inspection, Oil Level, Gearbox Axis 5
5 Maintenance activities, manipulator 5.1.5 Inspection, oil level, gearbox axis 5 5.1.5 Inspection, oil level, gearbox axis 5 Location of gear- The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Oil plug, filling Oil plug, draining Required equip- ment...
Page 687 5 Maintenance activities, manipulator 5.1.5 Inspection, oil level, gearbox axis 5 When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer! When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside the gearbox which in turn may: - damage seals and gaskets - completely press out seals and gaskets...
Page 688: Inspection, Oil Level Gearbox Axis 6
5 Maintenance activities, manipulator 5.1.6 Inspection, oil level gearbox axis 6 5.1.6 Inspection, oil level gearbox axis 6 Location of gear- The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0200000233 Gearbox axis 6 Oil plug, filling...
Page 689 5 Maintenance activities, manipulator 5.1.6 Inspection, oil level gearbox axis 6 When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside the gearbox which in turn may: - damage seals and gaskets - completely press out seals and gaskets - prevent the manipulator from moving freely Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure that protective gear like goggles and gloves are always worn during this work.
Page 690: Inspection, Balancing Device
5 Maintenance activities, manipulator 5.1.7 Inspection, balancing device 5.1.7 Inspection, balancing device Location of bal- The balancing device is located at the top rear of the frame as shown in the figure below. ancing device If damage is detected during inspection, a maintenance or an upgrade must be performed, depending on version of balancing device! Balancing device 3HAC 14678-1 and 3HAC 16189-1 requires maintenance, while 3HAC 12604-1 requires an upgrade.
Page 691 5 Maintenance activities, manipulator 5.1.7 Inspection, balancing device Equipment, etc. Spare part no. Art. no. Note Balancing device 3HAC 16907-1 IRB 6650. Includes balancing device 3HAC 16189-1! Standard toolkit 3HAC 15571-1 The contents are defined in sec- tion Standard toolkit on page 18! Other tools and proce- These procedures include refer- dures may be required.
Page 692 The springs inside the cylinder can cause a device" in the Repair Manual. tapping sound. Replace the balancing device or consult ABB Robotics. Check for dissonance from the piston rod. Squeaking can indicate worn plain bearings, internal contamination or insufficient lubrica- tion.
Page 693: Inspection, Cable Harness
5 Maintenance activities, manipulator 5.1.8 Inspection, cable harness 5.1.8 Inspection, cable harness Location of The manipulator cable harness, axes 1-4, is located as shown in the figure below. cabling axes 1-4 xx0200000097 Lower arm Cables attached with velcro straps and mounting plate Connectors at cable harness division point, R2.M5/6 Connectors at base Required equip-...
Page 694 5 Maintenance activities, manipulator 5.1.8 Inspection, cable harness Equipment, etc. Spare part no. Art. no. Note Other tools and proce- These procedures include dures may be required. references to the tools See references to these required. procedures in the step-by- step instructions below.
Page 695 5 Maintenance activities, manipulator 5.1.8 Inspection, cable harness Location of The manipulator cable harness, axes 5-6, is located as shown in the figure below. cabling axes 5-6 xx0200000234 Connectors at cable harness division point, R2.M5/6 Cable attachment, rear of upper arm Cable attachment, upper arm tube Inspection, cable The procedure below details how to inspect the cable harness of axes 5-6.
Page 696 5 Maintenance activities, manipulator 5.1.8 Inspection, cable harness Step Action Note Check the attachments at the rear of the upper arm and Shown in the figure Loca- in the upper arm tube. tion of cabling axes 5-6 on page 61! Check the connectors at the cable harness division.
Page 697: Inspection, Information Labels
5 Maintenance activities, manipulator 5.1.9 Inspection, information labels 5.1.9 Inspection, information labels Location of labels The figures below show the location of the information labels to be inspected. Wa rning Warning xx0200000236 Warning label "High temperature", 3HAC 4431-1 Warning sign, a symbol of a lightning flash (located on motor cover), 3HAC 1589-1 Instruction label "Safety instructions", 3HAC 4591-1 Warning label "Brake release", 3HAC 15334-1 3HAC 16246-1...
Page 698 5 Maintenance activities, manipulator 5.1.9 Inspection, information labels Lifti n g of robot Warning Warning xx0200000101 Instruction label "Lifting the robot", 3HAC 16420-1 Warning label "Robot can tip forward...", 3HAC 9191-1 Foundry logotype, 3HAC 8256-1 Warning label "Stored energy", 3HAC 9526-1 Required equip- ment Equipment, etc.
Page 699: Inspection, Mechanical Stop, Axis 1
5 Maintenance activities, manipulator 5.1.10 Inspection, mechanical stop, axis 1 5.1.10 Inspection, mechanical stop, axis 1 Location of The mechanical stop axis 1 is located at the base as shown in the figure below. mechanical stop xx0200000151 Mechanical stop (stop pin) Required equip- ment Equipment, etc.
Page 700: Inspection, Mechanical Stop, Axes 1, 2 And 3
5 Maintenance activities, manipulator 5.1.11 Inspection, mechanical stop, axes 1, 2 and 3 5.1.11 Inspection, mechanical stop, axes 1, 2 and 3 Location of The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3 mechanical stops (IRB 7600 shown).
Page 701 5 Maintenance activities, manipulator 5.1.11 Inspection, mechanical stop, axes 1, 2 and 3 Inspection, The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and mechanical stops Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Page 702: Inspection, Damper Axes 2-5
5 Maintenance activities, manipulator 5.1.12 Inspection, damper axes 2-5 5.1.12 Inspection, damper axes 2-5 Location of The figure below shows the location of all the dampers to be inspected. dampers xx0300000040 Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs) Damper, axis 4 (1 pc) Damper, axis 5 (2 pcs) Required equip-...
Page 703 5 Maintenance activities, manipulator 5.1.12 Inspection, damper axes 2-5 Inspection, damp- The procedure below details how to inspect the dampers, axes 2-5 Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 704: Inspection, Position Switch Axes 1, 2 And 3
5 Maintenance activities, manipulator 5.1.13 Inspection, position switch axes 1, 2 and 3 5.1.13 Inspection, position switch axes 1, 2 and 3 Location of posi- The illustration below shows the position switch for axis 1. tion switches xx0100000158 Position switch, axis 1 Set screw, cam Protection sheet Rail...
Page 705 5 Maintenance activities, manipulator 5.1.13 Inspection, position switch axes 1, 2 and 3 Position switch, axis 2 Set screw, cam Rail Rail attachment The illustration below shows the position switch for axis 3. xx0100000160 Position switch, axis 3 Set screw, cam Rail Rail attachment Required equip-...
Page 706 5 Maintenance activities, manipulator 5.1.13 Inspection, position switch axes 1, 2 and 3 Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 18! Other tools and proce- These procedures include ref- dures may be required.
Page 707: Inspection, Ul Signal Lamp
5 Maintenance activities, manipulator 5.1.14 Inspection, UL signal lamp 5.1.14 Inspection, UL signal lamp Location of UL The UL-lamp is located as shown in the figure below. Note that the position can differ lamp depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on the current harness for alternative positioning.
Page 708 5 Maintenance activities, manipulator 5.1.14 Inspection, UL signal lamp Equipment, etc. Spare part no. Art. no. Note Other tools and proce- These procedures include ref- dures may be required. erences to the tools required. See references to these procedures in the step-by-step instruc- tions below.
Page 709: Section 5.2: Changing Activities
5 Maintenance activities, manipulator 5.2.1 Oil change, gearbox axis 1 Section 5.2: Changing activities 5.2.1 Oil change, gearbox axis 1 Location of gear- The axis 1 gearbox is located between the frame and base as shown in the figure below. xx0200000228 Gearbox axis 1 Oil plug, inspection...
Page 710 5 Maintenance activities, manipulator 5.2.1 Oil change, gearbox axis 1 Changing, oil The procedure below details how to change the oil in gearbox axis 1. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 711 5 Maintenance activities, manipulator 5.2.1 Oil change, gearbox axis 1 Step Action Note/Illustration Close the rear cover by securing it with its attachment screws. Open the oil plug, filling. Shown in the figure Location of gearbox on page 75! Refill the gearbox with lubricating oil. Art.
Page 712: Oil Change, Gearbox Axis 2
5 Maintenance activities, manipulator 5.2.2 Oil change, gearbox axis 2 5.2.2 Oil change, gearbox axis 2 Different designs Between the axis 2 motor and gearbox there is a motor attachment which exists in two differ- ent designs. • The early design of the motor attachment is attached directly to the gearbox, with the front gearbox attachment screws (only some versions of IRB 6600).
Page 713 5 Maintenance activities, manipulator 5.2.2 Oil change, gearbox axis 2 Required equip- ment Equipment, etc. Spare part no. Art. no. Note Lubricating oil 3HAC 16843-1 Optimol Optigear RMO 150. Total amount with early design of motor attachment: 1,800 ml. Total amount with later design of motor attachment: 4,300 ml.
Page 714 5 Maintenance activities, manipulator 5.2.2 Oil change, gearbox axis 2 Step Action Note/Illustration Remove the oil plug, draining, and drain Shown in the figure Location of gearbox the gearbox oil using a hose with nipple on page 78! and an oil collecting vessel. Vessel capacity specified above! Draining is time-consuming.
Page 715: Oil Change, Gearbox, Axis 3
5 Maintenance activities, manipulator 5.2.3 Oil change, gearbox, axis 3 5.2.3 Oil change, gearbox, axis 3 Location of gear- The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equip-...
Page 716 5 Maintenance activities, manipulator 5.2.3 Oil change, gearbox, axis 3 Changing, oil The procedure below details how to change the oil in gearbox, axis 3. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 717: Oil Change, Gearbox, Axis 4
5 Maintenance activities, manipulator 5.2.4 Oil change, gearbox, axis 4 5.2.4 Oil change, gearbox, axis 4 Location of gear- The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining Required equip-...
Page 718 5 Maintenance activities, manipulator 5.2.4 Oil change, gearbox, axis 4 Changing, oil The procedure below details how to change the oil in gearbox, axis 4. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 719: Oil Change, Gearbox, Axis 5
5 Maintenance activities, manipulator 5.2.5 Oil change, gearbox, axis 5 5.2.5 Oil change, gearbox, axis 5 Location of gear- The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Oil plug, filling Oil plug, draining Required equip- ment Equipment, etc.
Page 720 5 Maintenance activities, manipulator 5.2.5 Oil change, gearbox, axis 5 When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains quicker than cold oil. When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer! When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside the gearbox which in turn may:...
Page 721: Oil Change, Gearbox Axis 6
5 Maintenance activities, manipulator 5.2.6 Oil change, gearbox axis 6 5.2.6 Oil change, gearbox axis 6 Location of gear- The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. The different robot versions have different gearbox designs. The amount of oil in the gearbox therefore varies depending on robot version.
Page 722 5 Maintenance activities, manipulator 5.2.6 Oil change, gearbox axis 6 Changing, oil The procedure below details how to change oil in gearbox, axis 6. Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 723: Section 5.3: Lubrication Activities
5 Maintenance activities, manipulator 5.3.1 Lubrication, balancing device bearing Section 5.3: Lubrication activities 5.3.1 Lubrication, balancing device bearing Location of bear- The figure below shows the location of the lubrication nipple etc. Note! The balancing device must be mounted on the manipulator when lubricating the bear- ing! xx0200000109 Ear (spherical roller bearing located inside)
Page 724 5 Maintenance activities, manipulator 5.3.1 Lubrication, balancing device bearing Lubrication, bal- The procedure below details how to lubricate the spherical roller bearing. ancing device bearing Please observe the following before commencing any repair work on the manipulator: - Motors and gears are HOT after running the robot! Burns may result from touching the motors or gears! - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! - Take any necessary measures to ensure that the manipulator does not collapse as parts are...
Page 725: Section 5.4: Cleaning Activities
5 Maintenance activities, manipulator 5.4.1 Cleaning, manipulator Section 5.4: Cleaning activities 5.4.1 Cleaning, manipulator General The protection class is IP 67, i.e. the manipulator is watertight. Activities This instruction specifies how to clean the manipulator. Periodicity The periodicity of cleaning the manipulator varies a great deal depending on the actual envi- ronment and function of the robot.
Page 726 5 Maintenance activities, manipulator 5.4.1 Cleaning, manipulator Required equip- ment Equipment, etc. Note Steam cleaner • Water pressure at nozzle: max. 2,500 kN/m (25 bar) • Type of nozzle: fan jet, min. 45°spread • Flow: max. 100 litres/min. • Water temperature: max. 80°C High pressure water •...
Page 727: Chapter 6: Maintenance Activities, Controller Cabinet
6 Maintenance activities, controller cabinet 6.0.1 Introduction Chapter 6: Maintenance activities, controller cabinet 6.0.1 Introduction General This chapter contains information on how to maintain the equipment in question, i.e. how to perform the preventive maintenance activities specified in the maintenance schedule for the same equipment.
Page 728: Section 6.1: Inspection Activities
6 Maintenance activities, controller cabinet 6.1.1 Inspection of controller cabinet, S4Cplus M2000A Section 6.1: Inspection activities 6.1.1 Inspection of controller cabinet, S4Cplus M2000A Inspection The procedure below details how to inspect the controller cabinet. Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through...
Page 729: Section 6.2: Replacement Activities
6 Maintenance activities, controller cabinet 6.2.1 Replacement of battery unit, controller Section 6.2: Replacement activities 6.2.1 Replacement of battery unit, controller Location of bat- The battery unit is located at the bottom of the controller. tery unit Rectifier xx0200000103 Battery unit Required equip- ment Equipment, etc.
Page 730 6 Maintenance activities, controller cabinet 6.2.1 Replacement of battery unit, controller Step Action Note/Illustration 1. Remove the battery unit by unscrew- ing its attachment screws (1). Rectifier xx0200000004 2. Pull the battery unit out. 3. Disconnect the three cables from the battery unit.
Page 731: Section 6.3: Cleaning Activities
6 Maintenance activities, controller cabinet 6.3.1 Cleaning of controller cabinet Section 6.3: Cleaning activities 6.3.1 Cleaning of controller cabinet Required equip- ment Equipment, etc. Art. no. Note Vacuum cleaner ESD Safe Cleaning agent, exterior cleaning Use rag with alcohol, for example, if necessary Internal cleaning The procedure below details how to clean the interior of the controller cabinet.
Page 732: Cleaning Computer Fans
6 Maintenance activities, controller cabinet 6.3.2 Cleaning computer fans 6.3.2 Cleaning computer fans Location of com- The fans are located as shown in the figure below: puter fans xx0200000002 Cover Screw Required equip- ment Equipment, etc. Spare part no. Art. no. Note Vacuum cleaner ESD Safe...
Page 733 6 Maintenance activities, controller cabinet 6.3.2 Cleaning computer fans Step Action Note/Illustration Remove the covers. Clean the fans with an ESD safe vacuum cleaner. Remount the covers. 3HAC 16246-1...
Page 734: Cleaning Drive Units And Air Outlet Device
6 Maintenance activities, controller cabinet 6.3.3 Cleaning Drive units and air outlet device 6.3.3 Cleaning Drive units and air outlet device Location of drive The illustration below shows the location of the drive units and air outlet device. units Drive units Air outlet device Required equip- ment...
Page 735 6 Maintenance activities, controller cabinet 6.3.3 Cleaning Drive units and air outlet device Step Action Illustration/Note Remove the bleeder resistor. Detailed in Repairs Manual section “Replacement of bleeder resistor”. Clean the Inside of the air outlet. Use an ESD safe vacuum cleaner. Clean the back side of the drive units.
Page 736: Cleaning Air Outlet
6 Maintenance activities, controller cabinet 6.3.4 Cleaning Air outlet 6.3.4 Cleaning Air outlet Location of air The illustration below shows the location of the air outlet shaft outlet Air outlet Required equip- ment Equipment, etc. Spare part no. Art. no. Note Vacuum cleaner ESD Safe...
Page 737 6 Maintenance activities, controller cabinet 6.3.4 Cleaning Air outlet Refitting The procedure below details how to refit the Drive units, bleeder resistor and system fan unit. Please observe the following before commencing any repair work on the controller: Turn off all electric power supplies to the cabinet! Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will be destroyed if subjected to it! Before handling, make sure you are connected to earth through a special ESD wrist bracelet or similar.
Page 738: Cleaning Drain Filter
6 Maintenance activities, controller cabinet 6.3.5 Cleaning Drain filter 6.3.5 Cleaning Drain filter Location of drain The illustration below shows the location of the drain filter. filter Filter holder M5 screw Drain filter Required equip- ment Equipment, etc. Spare part no. Art no. Note Filter 3HAC 5393-2...
Page 739 6 Maintenance activities, controller cabinet 6.3.5 Cleaning Drain filter Step Action Note/Illustration 1. Place the computer unit in the service posi- Detailed in Repairs Manual, section, tion. “Putting the computer unit in service position”. 2. Loosen the M5 screw, pos. 2 in illustration. 3.
Page 740 6 Maintenance activities, controller cabinet 6.3.5 Cleaning Drain filter 3HAC 16246-1...
Page 741 Repair Manual, part 2 (Circuit Diagrams) Industrial Robot IRB 6600 - 225/2.55 IRB 6600 - 175/2.8 IRB 6600 - 175/2.55 IRB 6650 - 200/2.75 IRB 6650 - 125/3.2 M2000A...
Page 743 Repair Manual, part 2 (Circuit Diagrams) IRB 6600/6650 M2000A 3HAC 16247-1 Revision A...
Page 744 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re- sponsibility for any errors that may appear in this manual. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.
Page 745 0.0.1 Overview 0.0.1 Overview About This This information product is a manual containing circuit diagrams for both the manipulator Manual and the controller cabinet. Usage This manual should be used during installation/repair/maintenance work. Who Should Read This manual is intended for: This Manual? •...
Page 746 0.0.1 Overview 3HAC 16247-1...
Page 747 Circuit Diagram 3HAC 13347-1 / Rev. 01 CONTENTS Sheet Contents ........................101 Connection Point Location ...................102 Legend ..........................103 Brake Release Unit .......................104 Service brake release unit (IRB 7600)...............104.1 Serial Measurement Board ...................105 Axis 1..........................106 Axis 2..........................107 Axis 3..........................108 Axis 4..........................109 Axis 5 (IRB 7600) ......................110 Axis 5 (IRB 6600) .....................110.1 Axis 6..........................111 Customer Power/Signal/Bus Connections..............112...
Page 749 Circuit Diagram 3HAC 13347-1...
Page 751 Circuit Diagram 3HAC 13347-1...
Page 753 Circuit Diagram 3HAC 13347-1...
Page 755 Circuit Diagram 3HAC 13347-1...
Page 757 Circuit Diagram 3HAC 13347-1...
Page 759 Circuit Diagram 3HAC 13347-1...
Page 761 Circuit Diagram 3HAC 13347-1...
Page 763 Circuit Diagram 3HAC 13347-1...
Page 765 Circuit Diagram 3HAC 13347-1...
Page 767 Circuit Diagram 3HAC 13347-1...
Page 769 Circuit Diagram 3HAC 13347-1...
Page 771 Circuit Diagram 3HAC 13347-1...
Page 773 Circuit Diagram 3HAC 13347-1...
Page 775 Circuit Diagram 3HAC 13347-1...
Page 777 Circuit Diagram 3HAC 13347-1...
Page 779 Circuit Diagram 3HAC 13347-1...
Page 781 Circuit Diagram 3HAC 13347-1...
Page 783 Circuit Diagram 3HAC 13347-1...
Page 785 Circuit Diagram 3HAC 13347-1...
Page 787 Circuit Diagram 3HAC 13347-1...
Page 788 ABB Automation Technology Products AB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...
Page 789 Circuit Diagram 3HAC 5582-2/Rev. 03 Contents Page 1 General Information ......................1 Block Diagram......................1-1 View of Control Cabinet....................1-2 View of Control Cabinet....................1-3 Designation........................1-4 Designation........................1-5 2 Mains Connection and Power Supply ................1 Mains Connection......................2-1 Transformer Unit 400-600V..................
Page 790 Circuit Diagram 3HAC 5582-2/Rev. 03 Contents Page Rectifier, fans and bleeder, IRB 66X0, 7600 ............... 5-15 Servo drive system, IRB 66X0, 7600................5-16 Control cable, IRB 66X0, 7600..................5-17 6 External Axes ........................1 External Axes ....................... 6-1 Axes Computer 2 and Connector Board............... 6-2 Expansion Board Axis Connector Board ..............
Page 791 Circuit Diagram 3HAC 5582-2/Rev. 03 Contents Page Extension Cable Teach Pendant ................... 8-9 Time Relay ........................8-10 External I/O CAN-BUS Connection ................8-11 Customer power/signal/Profibus, IRB 6400R .............. 8-12 LAN Ethernet connection..................... 8-13 Customer power/CAN-BUS IRB 640/6400S ............... 8-14 Customer cable power/signal CAN-BUS IRB 6600/7600 ........... 8-15 Customer cable power/signal Profibus IRB 66X0/7600 ..........
Page 792 Circuit Diagram 3HAC 5582-2/Rev. 03 Contents Page Circuit Diagram S4Cplus...
Page 793 Circuit Diagram 3HAC 5582-2...
Page 795 Circuit Diagram 3HAC 5582-2...
Page 797 Circuit Diagram 3HAC 5582-2...
Page 799 Circuit Diagram 3HAC 5582-2...
Page 801 Circuit Diagram 3HAC 5582-2...
Page 803 Circuit Diagram 3HAC 5582-2...
Page 805 Circuit Diagram 3HAC 5582-2...
Page 807 Circuit Diagram 3HAC 5582-2...
Page 809 Circuit Diagram 3HAC 5582-2...
Page 811 Circuit Diagram 3HAC 5582-2...
Page 813 Circuit Diagram 3HAC 5582-2...
Page 815 Circuit Diagram 3HAC 5582-2...
Page 817 Circuit Diagram 3HAC 5582-2...
Page 819 Circuit Diagram 3HAC 5582-2...
Page 821 Circuit Diagram 3HAC 5582-2...
Page 823 Circuit Diagram 3HAC 5582-2...
Page 825 Circuit Diagram 3HAC 5582-2...
Page 827 Circuit Diagram 3HAC 5582-2...
Page 829 Circuit Diagram 3HAC 5582-2...
Page 831 Circuit Diagram 3HAC 5582-2...
Page 833 Circuit Diagram 3HAC 5582-2...
Page 835 Circuit Diagram 3HAC 5582-2...
Page 837 Circuit Diagram 3HAC 5582-2...
Page 839 Circuit Diagram 3HAC 5582-2...
Page 841 Circuit Diagram 3HAC 5582-2...
Page 843 Circuit Diagram 3HAC 5582-2...
Page 845 Circuit Diagram 3HAC 5582-2...
Page 847 Circuit Diagram 3HAC 5582-2...
Page 849 Circuit Diagram 3HAC 5582-2...
Page 851 Circuit Diagram 3HAC 5582-2...
Page 853 Circuit Diagram 3HAC 5582-2...
Page 855 Circuit Diagram 3HAC 5582-2...
Page 857 Circuit Diagram 3HAC 5582-2...
Page 859 Circuit Diagram 3HAC 5582-2...
Page 861 Circuit Diagram 3HAC 5582-2...
Page 863 Circuit Diagram 3HAC 5582-2...
Page 865 Circuit Diagram 3HAC 5582-2...
Page 867 Circuit Diagram 3HAC 5582-2...
Page 869 Circuit Diagram 3HAC 5582-2...
Page 871 Circuit Diagram 3HAC 5582-2...
Page 873 Circuit Diagram 3HAC 5582-2...
Page 875 Circuit Diagram 3HAC 5582-2...
Page 877 Circuit Diagram 3HAC 5582-2...
Page 879 Circuit Diagram 3HAC 5582-2...
Page 881 Circuit Diagram 3HAC 5582-2...
Page 883 Circuit Diagram 3HAC 5582-2...
Page 885 Circuit Diagram 3HAC 5582-2...
Page 887 Circuit Diagram 3HAC 5582-2...
Page 889 Circuit Diagram 3HAC 5582-2...
Page 891 Circuit Diagram 3HAC 5582-2...
Page 893 Circuit Diagram 3HAC 5582-2...
Page 895 Circuit Diagram 3HAC 5582-2...
Page 897 Circuit Diagram 3HAC 5582-2...
Page 899 Circuit Diagram 3HAC 5582-2...
Page 901 Circuit Diagram 3HAC 5582-2...
Page 903 Circuit Diagram 3HAC 5582-2...
Page 905 Circuit Diagram 3HAC 5582-2...
Page 907 Circuit Diagram 3HAC 5582-2...
Page 909 Circuit Diagram 3HAC 5582-2...
Page 911 Circuit Diagram 3HAC 5582-2...
Page 913 Circuit Diagram 3HAC 5582-2...
Page 915 Circuit Diagram 3HAC 5582-2...
Page 917 Circuit Diagram 3HAC 5582-2...
Page 919 Circuit Diagram 3HAC 5582-2...
Page 921 Circuit Diagram 3HAC 5582-2...
Page 923 Circuit Diagram 3HAC 5582-2...
Page 925 Circuit Diagram 3HAC 5582-2...
Page 927 Circuit Diagram 3HAC 5582-2...
Page 929 Circuit Diagram 3HAC 5582-2...
Page 931 Circuit Diagram 3HAC 5582-2...
Page 933 Circuit Diagram 3HAC 5582-2...
Page 935 Circuit Diagram 3HAC 5582-2...
Page 937 Circuit Diagram 3HAC 5582-2...
Page 939 Circuit Diagram 3HAC 5582-2...
Page 941 Circuit Diagram 3HAC 5582-2...
Page 943 Circuit Diagram 3HAC 5582-2...
Page 945 Circuit Diagram 3HAC 5582-2...
Page 947 Circuit Diagram 3HAC 5582-2...
Page 949 Circuit Diagram 3HAC 5582-2...
Page 951 Circuit Diagram 3HAC 5582-2...
Page 953 Circuit Diagram 3HAC 5582-2...
Page 955 Circuit Diagram 3HAC 5582-2...
Page 957 Circuit Diagram 3HAC 5582-2...
Page 959 Circuit Diagram 3HAC 5582-2...
Page 961 Circuit Diagram 3HAC 5582-2...
Page 963 Circuit Diagram 3HAC 5582-2...
Page 965 Circuit Diagram 3HAC 5582-2...
Page 967 Circuit Diagram 3HAC 5582-2...
Page 969 Circuit Diagram 3HAC 5582-2...
Page 971 Circuit Diagram 3HAC 5582-2...
Page 973 Circuit Diagram 3HAC 5582-2...
Page 975 Circuit Diagram 3HAC 5582-2...
Page 977 Circuit Diagram 3HAC 5582-2...
Page 979 Circuit Diagram 3HAC 5582-2...
Page 981 Circuit Diagram 3HAC 5582-2...
Page 983 Circuit Diagram 3HAC 5582-2...
Page 985 Circuit Diagram 3HAC 5582-2...
Page 987 Circuit Diagram 3HAC 5582-2...
Page 989 Circuit Diagram 3HAC 5582-2...
Page 991 Circuit Diagram 3HAC 5582-2...
Page 993 Circuit Diagram 3HAC 5582-2...
Page 995 Circuit Diagram 3HAC 5582-2...
Page 997 Circuit Diagram 3HAC 5582-2...
Page 999 Circuit Diagram 3HAC 5582-2...
Page 1001 Circuit Diagram 3HAC 5582-2...
Page 1003 Circuit Diagram 3HAC 5582-2...
Page 1005 Circuit Diagram 3HAC 5582-2...
Page 1007 Circuit Diagram 3HAC 5582-2...
Page 1009 Circuit Diagram 3HAC 5582-2...
Page 1011 Circuit Diagram 3HAC 5582-2...
Page 1013 Circuit Diagram 3HAC 5582-2...
Page 1015 Circuit Diagram 3HAC 5582-2...
Page 1017 Circuit Diagram 3HAC 5582-2...
Page 1019 Circuit Diagram 3HAC 5582-2...
Page 1020 ABB Automation Technology Products AB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 6600 - 225/2.55 Irb 6600 - 175/2.8 Irb 6650 - 125/3.2 Irb 6650 - 200/2.75

ABB IRB 6600 - 175/2.55 User Manual

Chapter 6: Maintenance Activities, Controller Cabinet

Quick Links

Related Manuals for ABB IRB 6600 - 175/2.55

Summary of Contents for ABB IRB 6600 - 175/2.55

This manual is also suitable for:

Table of Contents