ABB IRB 6640 Foundry Prime Product Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Robotics
  5. IRB 6640 Foundry Prime
  6. Product manual

ABB IRB 6640 Foundry Prime Product Manual

Hide thumbs
1
2
3
4
Table Of Contents
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
Table of Contents

Advertisement

Quick Links

ROBOTICS
Product manual
IRB 6640 Foundry Prime

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the IRB 6640 Foundry Prime and is the answer not in the manual?

Questions and answers

Related Manuals for ABB IRB 6640 Foundry Prime

Summary of Contents for ABB IRB 6640 Foundry Prime

  • Page 1 ROBOTICS Product manual IRB 6640 Foundry Prime...
  • Page 2 Trace back information: Workspace R18-1 version a9 Checked in 2018-03-22 Skribenta version 5.2.025...
  • Page 3 Product manual IRB 6640 Foundry Prime - 235/2.55 IRB 6640 Foundry Prime - 185/2.8 IRC5 Document ID: 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    2.7.11 Installing the over pressure limiter unit ............2.7.11.1 Installing the over pressure limiter on wall ........2.7.11.2 Installing the over pressure limiter unit on robot base ......Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 6 Apply Mercasol on output shaft axis 2 ............3.6.6 Apply Mercasol on output shaft axis 3 ............Cleaning activities ..................... 3.7.1 Cleaning the IRB 6640 Foundry Prime ............Repair Introduction ...................... General procedures ................... 4.2.1 Performing a leak-down test ..............
  • Page 7 Decommissioning of balancing device ..............Reference information Introduction ...................... Applicable standards ..................Unit conversion ....................Screw joints ....................Weight specifications ..................Standard tools ....................Special tools ....................Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 8 Dismounting and mounting tool 3HAC028920-001 ........... Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Circuit diagrams Circuit diagrams ....................Index Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 9: Overview Of This Manual

    • repair personnel. Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
  • Page 10 • Robot designations are adjusted in sub-headings in section Robot transportation precautions on page Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 11: Product Manual - Irb

    Replacing gearbox axis 1 on page 387. • Changed article number 3HAA1001-294 to 3HAC042534-001 throughout manual. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 12 • Drying time for Mercasol added. • Removed article number for press fixture (for pressing the pinion of the axis-5 motor). The fixture is not sold by ABB. • Reference added from general information to installation regarding pressurized components. •...
  • Page 13 • New spare part number brake release board (was DSQC563). • Information about myABB Business Portal added. • Added Nickel in Environmental information. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 14: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 15 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 16: How To Read The Product Manual

    Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 17: Important Information About Robots With Protection Type Foundry Prime

    For more information, see Pressurized components on page Cleaning Special procedures are needed when cleaning the Foundry Prime robot. See section Cleaning the IRB 6640 Foundry Prime on page 210. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N...
  • Page 18 This page is intentionally left blank...

  • Page 19: Safety

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
  • Page 20 Grippers/end effectors must be designed so that they retain work pieces in the event of a power failure or a disturbance to the controller. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 21 1.1.1 Limitation of liability Continued Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected. CAUTION Ensure that a gripper is prevented from dropping a work piece, if such is used.

  • Page 22: Protective Stop And Emergency Stop

    1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 23: Safety Actions

    1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 24: Emergency Release Of The Robot Axes

    When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 25: Make Sure That The Main Power Has Been Switched Off

    DANGER Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 26: Safety Risks

    Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 27 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

  • Page 28: Moving Robots Are Potentially Lethal

    Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 29: First Test Run May Cause Injury Or Damage

    Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 30: Work Inside The Working Range Of The Robot

    Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 31: Enabling Device And Hold-To-Run Functionality

    How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 32: Risks Associated With Live Electric Parts

    The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 33 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 34: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 35: Hot Parts May Cause Burns

    Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 36: Safety Risks Related To Pneumatic/Hydraulic Systems

    Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 37: Brake Testing

    3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 38: Safety Risks During Handling Of Batteries

    Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 39: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    Possible pressure build-up in gearbox Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 40 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 41: Safety Signals And Symbols

    ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 42 Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 43: Safety Symbols On Product Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 44 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 45 The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 46 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 47 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 48 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 49: Installation And Commissioning

    Safety on page 19 before performing any installation work. Note If the IRB 6640 Foundry Prime is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: •...

  • Page 50: Installation And Operational Requirements For Foundry Prime Robots

    Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 51 >200 L/min Pressurizing equipment ABB recommends a safety valve (if not included) set at 0.4 bar, pressure sensor set at 0.2-0.3 bar or regulator set for maximum 0.3 bar to be attached on the pressure side of the air system.
  • Page 52 The sealing joints between the moving parts on the wrist must not be exposed to high pressure water. Rebounding high pressure water jet must be avoided. ABB recommends using a tool design with integrated covers that protect the wrist from direct or indirect high pressure water jet.
  • Page 53 The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independent of Motors On/Off mode, start-up and shut down periods. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 54: Design 1 And Design 2 Of Irb 6640

    Design 2 has: • two ears on the lower arm as shown in the figure for design 2 Design 1 xx0800000401 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 55 2 Installation and commissioning 2.3 Design 1 and Design 2 of IRB 6640 Continued Design 2 xx0800000402 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 56: Robot Transportation Precautions

    Pre-installation procedure on page 62 Method 2 - transportation with a tool mounted to the robot Transportation according to method 2 is approved by ABB, only if use of method 1 is not possible. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N ©...
  • Page 57 Always read and follow the instructions in section Securing the robot with a transport support on page 60 • Always place the robot in the ABB recommended transport position for robot with tool, described in sub section Transport position with a transport support on page •...
  • Page 58 Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 6640 Foundry Prime xx0800000040 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 59 2.4 Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 6640 Foundry Prime xx0800000039 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 60: Securing The Robot With A Transport Support

    It must be done with great care and only when absolutely necessary. Fitting the transport support Illustration for fitting the transport support xx0800000062 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 61 Use the brake release for axis 5 and 6 to reach the final resting position for the tool, see the section Manually releasing the brakes on page 78 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 62: Unpacking

    It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
  • Page 63 Floor mounted Force Endurance load (in operation) Max. load (emergency stop) Force xy ± 8.5 kN ± 20.4 kN Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 64 +55° C Maximum ambient temperature (less than 24 hrs) +70° C Maximum ambient humidity 100% at constant temperature (gaseous only) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 65 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Foundry Prime IP 67 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 66: Working Range And Type Of Motion

    903 mm 1549 mm 1814 mm IRB 6640ID-2.75 3219 mm 268 mm 2755 mm 961 mm 1682 mm 1999 mm Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 67 4 and 6 together. Bend motion IRB 6640: +120° to -120° IRB 6640ID: +100º to -100º Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 68 See product manual SpotPack/DressPack IRB 6640 chapter Installation section DressPack cable package. Art. no. can be found in section Working range and type of motion on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 69: Risk Of Tipping/Stability

    This figure shows the robot in its shipping position and transportation position. xx0600003400 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 70: On-Site Installation

    If the robot is dressed, this must be taken into consideration when the robot is be- ing lifted. xx0600003400 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 71 The fork lift accessory is fitted on the robot as shown in the figure. xx0600002910 Fork lift pocket Attachment screw M20x60 quality 8.8 (2 pcs x4) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 72 A Fork lift pocket (4 pcs) B Attachment screw M20x60 quality 8.8 (2 pcs x4) Verify that all four fork lift pockets are properly secured before lifting. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 73: Lifting The Robot With Fork Lift Truck

    Verify that all four fork lift pockets are properly secured before lifting. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 74 If lifting with fewer than four fork lift pockets fitted, there is a risk of accidents! xx0600002911 IRB 6640 xx0600003401 IRB 460 xx1000001159 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 75 Continued Action Note Remove the attachment bolts securing the robot to the foundation. CAUTION The IRB 6640 Foundry Prime robot weighs 1,340 kg (IRB6640), 1,405 kg (IRB6640ID) All lifting accessories used must be sized accordingly! Carefully lift the robot. WARNING...

  • Page 76: Lifting Robot With Roundslings

    CAUTION Note The IRB 6640 Foundry Prime robot weighs If the robot is equipped with fork lift 1,340 kg (IRB6640), 1,405 kg (IRB6640ID) . pockets an extra weight of 90 kg must be added to the robot weight!
  • Page 77 Do not stretch! Lifting eye M20 (4 pcs). Note! Fit lifting eyes in the rear holes. Holes for lifting eyes in the robotbase. (Rear holes) Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 78: Manually Releasing The Brakes

    The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 79 Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 80: Lifting The Base Plate

    Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 81: Securing The Base Plate

    E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 82 2 Installation and commissioning 2.7.5 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 83 The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate. xx1500000312 Orienting grooves (3 pcs) Levelling bolts, attachment holes (4 pcs) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 84 This section details how to secure the base plate to the foundation. Action Note Make sure the foundation is levelled. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 85 0.3 mm. If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 86: Orienting And Securing The Robot

    Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 87 Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 88 This illustration shows the hole configuration used when securing the robot. xx0600003403 Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0600003404 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 89: Fitting Equipment On Robot

    Note! Extra equipment may not be mounted on the lower arm of IRB 6640ID! Note! Extra equipment may not be fitted on the lower arm of Cleanroom robots! 4 x M12 xx0600003405 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 90 IRB 6640ID - 2.55 400 mm 13 mm 40 mm IRB 6640ID - 2.75 500 mm 13 mm 30 mm Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 91 IRB 6640 - 3.2 1592 mm 200 mm IRB 6640ID 1142 mm 290 mm IRB 6640ID 1142 mm 290 mm xx1000000158 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 92 Illustration, fitting of extra equipment on frame The mounting holes available for fitting extra equipment on the frame are shown below. xx0600003416 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 93 There are different versions of the turning disc, as shown in the illustrations below. xx0200000397 Turning disk type 1 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 94 When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. Standard screws with quality 8.8 may be used when fitting other equipment to the mounting holes. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 95: Surface Inspection Before Start-Up - Foundry Prime

    Protect attachment bolts and washers at the base Protect the attachment bolts and washers (M24x100) at the base from physical obstructions and splashes with appropriate shield. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 96: Loads Fitted To The Robot, Stopping Time And Braking Distances

    The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 97: Signal Lamp (Option)

    The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 98: Installing The Over Pressure Limiter Unit

    2.7.11 Installing the over pressure limiter unit General ABB recommends the over pressure unit to be placed away from the robot, preferably attached on a nearby located wall to minimize exposure to water and detergent. Direct contact to water or detergent shall be avoided as it will decrease the lifetime of the over pressure limiter unit.

  • Page 99: Installing The Over Pressure Limiter On Wall

    2.7.11.1 Installing the over pressure limiter on wall General ABB recommends the over pressure unit to be placed away from the robot, preferably attached on a nearby located wall to minimize exposure to water and detergent. Direct contact to water or detergent shall be avoided as it will decrease the lifetime of the over pressure limiter unit.
  • Page 100 These are further detailed in the section First test run may cause injury or damage on page Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 101 Disconnect the air hose from the unit. xx1700001150 Disconnect the air hose from the the robot base. xx1700001906 Remove the unit from the wall. xx1700001151 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 102: Installing The Over Pressure Limiter Unit On Robot Base

    2.7.11.2 Installing the over pressure limiter unit on robot base General ABB recommends the over pressure unit to be placed away from the robot, preferably attached on a nearby located wall to minimize exposure to water and detergent. Direct contact to water or detergent shall be avoided as it will decrease the lifetime of the over pressure limiter unit.
  • Page 103 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 104 Attach the over pressure limiter unit to the robot base. xx1700001901 Connect the air hose to the unit. xx1700001902 Refit the top cover. xx1700001903 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 105 Disconnect the air hose from unit. xx1700001904 Remove the top cover from the robot base. xx1700001905 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 106 2.7.11.2 Installing the over pressure limiter unit on robot base Continued Action Note Disconnect the air hose from the unit. xx1700001902 Remove the unit from the robot base. xx1700001901 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 107: Restricting The Working Range

    Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 108: Mechanically Restricting The Working Range Of Axis 1

    Attachment screw plus washer, M12 x 40 quality 12.9 (2 pcs) Fixed mechanical stop Mechanical stop pin axis 1 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 109 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 110: Mechanically Restricting The Working Range Of Axis 2

    • hydraulic pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 111 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 112: Mechanically Restricting The Working Range Of Axis 3

    The figure shows IRB 7600 but the principle is the same. xx0300000048 Additional mechanical stops Fixed mechanical stop Attachment screw M16x60 quality 12.9 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 113 465. Technical reference manu- Art. no. is specified in section Refer- al - System parameters ences on page Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 114 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 115: Electrical Connections

    3HAC026787-001 Robot cable, power: 15 m 3HAC026787-002 Robot cable, power: 22 m 3HAC026787-003 Robot cable, power: 30 m 3HAC026787-004 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 116 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1500001603 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 117: Start Of Robot In Cold Environments

    If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 118 This page is intentionally left blank...

  • Page 119: Maintenance

    To eliminate these risks appropriate equipment and procedures are required when installing, cleaning, maintaining, and repairing ABB Foundry Prime robots. An extended maintenance program including service activities and schedule is required.
  • Page 120 Continued Warranty claims Warranty claims for defect products due to misuse or failure to fulfil operational and maintenance requirements will not be approved. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 121: Maintenance Schedule And Expected Component Life

    Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 6640 Foundry Prime: • Calendar time: specified in months regardless of whether the system is running or not.

  • Page 122: Maintenance Schedule

    Every: • 2 months at start up • 6 months Analysis Oil gearbox axis 1-6 Every: • 6 months Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 123 If the water content in oil is more than 3%, analyze the new oil within 2 months. Repeatedly high water content in oil indicates wear of radial sealing in the gearbox. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 124 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 125: Expected Component Life

    5 is not calculated by SIS (See the Operating manual - Service Information System). In some applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB Robotics Service team for more information.
  • Page 126 3 Maintenance 3.2.3 Expected component life Continued • installation, maintenance, and repair procedures • the operation cycle of the robot. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 127: Inspection Activities

    These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 128 Further information about how to fill with oil is found in section Changing oil, axis-1 gearbox on page 170. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 129: Inspecting The Oil Level In Axis-2 Gearbox

    Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 130 168. Filling of oil is detailed further in the section Filling, oil on page 174. Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 131: Inspecting The Oil Level In Axis-3 Gearbox

    168. Standard toolkit Content is defined in section Standard tools on page 465. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 132 Measure the oil level. Required oil level: 0-20 mm xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 133 Further information about how to fill the oil may be found in the section Filling, oil on page 178. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 134: Inspecting The Oil Level In Axis-4 Gearbox

    Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 135 Further information about how to fill the oil may be found in the section Filling, oil on page 180. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 136: Inspecting The Oil Level In Axis-5 Gearbox

    The figure above shows the wrist unit of IRB 6600 and IRB 6650 Oil plug, filling and inspection Oil plug, draining Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 137 Safety risks during work with gearbox lubricants (oil or grease) on page Move the robot upper arm to a horizontal position. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 138 Further information about how to fill the oil may be found in the section Filling, oil, axis 5 on page 183. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 139: Inspecting The Oil Level In Axis-6 Gearbox

    Oil plug, filling and inspection Oil plug, draining xx0400001092 Type 2 Axis-6 gearbox Oil plug, filling and inspection Oil plug, draining Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 140 These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 141 Slowly turn axis 4, while adjusting axis 6 so that the oil plug, draining always faces upwards. Turn axis 4 until the axis-4 angle reads -45° to -55°. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 142 • hydraulic pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 143 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 144: Inspecting The Balancing Device

    Balancing device Piston rod (inside balancing device) Fork / Link ear Shaft Retaining ring, bore Attachments in cradle (rear bearing) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 145 297. Art. no. for the kit and the documentation are specified in section Required equipment on page 145. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 146 Check for dissonance If dissonance is detected... from... • balancing device (a ...replace the balancing device or consult ABB Robotics. tapping sound, How to replace the device is detailed in section Repla- caused by the springs cing the balancing device (design 1) on page 302.
  • Page 147 Leaks at o-rings, sealings etc. are not acceptable and must be attended to immediately to avoid damage to the bearing. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 148 Replacement of the complete bearing is also described in section Replace- ment of spherical roller bearing, balan- cing device on page 297. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 149 Inspection points, balancing device on page 144. Keep the areas around the balancing device clean and free from objects, such as service tools. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 150: Inspecting The Cable Harness

    Inspection of axes 5-6 is described in: Location of cabling axes 5-6 on page 153 Inspection, cable harness, axes 5-6 on page 153. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 151 Lower arm SMB/BU unit (battery pack RMU 3HAC16831-1 is shown, note that there are different battery versions) Connectors at base Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 152 Replace the cable harness if wear, cracks or Detailed in section Replacing cable damage is detected. harness, axes 1-6 on page 222. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 153 Shown in the figure Location of cabling per arm and in the upper arm tube. axes 5-6 on page 153. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 154 Replace the cable harness if wear, cracks or Replacing cable harness, axes 1-6 damage is detected. on page 222. Replacement of cabling, axis 5 mo- tor on page 237. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 155: Inspection Of Air Hoses (Foundry Prime)

    Pressurize by opening the cut off valve. Spray suspected leak areas with leak detec- tion spray. Note Bubbles indicate a leak. When the leak is localized: correct the leak. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 156: Inspection Of Surface Treatment (Foundry Prime)

    Use this procedure to inspect the surface treatment on Foundry Prime robots. Action Information Inspect all painted surfaces for damages. Repair damages as described in the instruc- tion included in the spare part kit. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 157: Inspecting The Information Labels

    Warning label concerning shutting off power Serial no. from rating label Information labels about type of oil, at gearboxes and at robot base Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 158 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare parts on page 487. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 159: Inspecting The Axis-1 Mechanical Stop Pin

    The axis-1 mechanical stop is located as shown in the figure. xx0600003436 Mechanical stop pin, axis 1 Fixed mechanical stop Required equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 160 If the mechanical stop pin is bent or damaged, it must be replaced. Note The expected life of gearboxes can be reduced after collision with the mechanical stop. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 161: Inspecting The Additional Mechanical Stops

    The figures shows the location of the additional mechanical stops on axes 1, 2 and xx0600002938 Additional stop, axis 1 Attachment screws and washers (2 pcs) Fixed stop Mechanical stop pin, axis 1 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 162 Attachment screw and washer • Document for mechanical stop pin Standard toolkit Content is defined in section Standard tools on page 465. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 163 Correct attachment screws: • Axis 1: M12 x 40, quality 12.9. • Axis 2: M16 x 50 • Axis 3: M16 x 60 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 164: Inspecting The Damper On Axes

    Damper 2, axis 5 3HAC021675-001 IRB 6640ID (2 pcs) Standard toolkit 3HAC15571-1 Content is defined in section Standard tools on page 465. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 165 If any damage is detected, the damper must be re- Art. no. is specified in Required placed with a new one! equipment on page 164. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 166: Inspecting The Signal Lamp (Option)

    To be replaced if damage is detected. page 487. Standard toolkit Content is defined in section Stand- ard tools on page 465. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 167 3 (=24V). • inspecting the cabling. Replace the cabling if a fault is detected. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 168: Changing Activities

    Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
  • Page 169 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 170: Changing Oil, Axis-1 Gearbox

    Content is defined in section ment Special tools on page 466. Standard toolkit Content is defined in section Standard tools on page 465. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 171 Drain as much oil as possible. See Safety risks during work with gearbox lubricants (oil or grease) on page Refit the oil plug, draining. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 172 168. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 173: Changing Oil, Axis-2 Gearbox

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 174 • hydraulic pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 175 129. page 168. Note Don´t mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 176: Changing Oil, Axis-3 Gearbox

    Oil exchange equipment 3HAC021745-001 Content is defined in section Special tools on page 466. Oil collecting vessel Capacity: 3,000 ml. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 177 Refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 178 168. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 179: Changing Oil, Axis-4 Gearbox

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 180 • hydraulic pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 181 Type and amount of oil in gearboxes on page 168. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 182: Changing Oil, Axis-5 Gearbox

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 183 Before proceeding, please read the safety inform- ation in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 184 Type and amount of oil in gearboxes on page 168. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 185: Changing Oil, Axis-6 Gearbox

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 186 • hydraulic pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 187 Refit the oil plug. Tightening torque: 24 Nm. Inspect the oil level. Detailed in the section Inspecting the oil level in axis-6 gearbox on page 139. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 188: Replacing The Smb Battery

    Battery pack with a 2-pole battery contact (DSQC) xx0600003444 Cover, battery box SMB battery pack with 2-pole battery contact. Cable, battery Battery holder Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 189 Spare part no. Note Battery unit For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare parts approved equivalent. on page 487 Standard toolkit Content is defined in section...
  • Page 190 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 188. with a specified spare part or with an ABB- ap- proved equivalent. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N...
  • Page 191 219 Update the revolution counters. Detailed in chapter Calibration - section Updating revolution coun- ters on page 444. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 192 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 193: Analysis Activities

    Normal replacement interval is required for the gearbox. 3000 6000 9000 12000 15000 xx0600003156 • A: Water content in gearbox oil • B: Months or hours in operation Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 194: Lubrication Activities

    Location of bearing (Design 2) Note The spherical roller bearing of design 2 with solid-oil does not need any scheduled lubrication. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 195 Grease 3HAC042534-001 Optimol PDO, 20 ml Lubrication nipple Normally not fitted to the link ear at delivery. Grease pump Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 196 Remove the lubrication nipple, and refit the M6 x 10, washer: D=6,4/12 T=1,6 upper securing screw and washer. Tightening torque: 6 Nm. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 197 Check for leakage - Design 1 on no incorrect leakage from the o-rings. page 146. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 198: Rust Preventive Measures, Bearing Axis 1 (Foundry Prime)

    The bearing axis 1 is located as shown in the illustration. (View from above). xx0700000445 Cable guide Required equipment Equipment Art. no. Note Brush Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 199 Remove the cable guide. xx0700000445 Parts: • A: Cable guide Wipe the surface under the cable guide. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 200 Refit the cable guide. Apply Sikaflex 521FC outside the cable guide as shown in the figure. xx1000000372 • A: Sikaflex 521FC • B: Cable guide Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 201: Rust Preventive Measures, Sealing Axis 4 (Foundry Prime)

    The procedure describes how to apply rust preventive on sealing axis 1. Action Note Put the robot in a suitable position. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 202 Remove the cable guide that covers the sealing. xx0600002871 Parts: • A: Cable guide Wipe the surface under the cable guide. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 203 Parts: • A: Radial sealing and rear part of tube • B: Cable guide Refit the radial sealing and cable guide. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 204: Rust Preventive Measures, Support Bearing In Wrist (Foundry Prime)

    See refer- ences to the tools required. ences to these procedures in the step-by-step instructions below. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 205 Refit the hose clamp. Connect the air hose to motor axis 6. Perform a leakdown test. Inspection of air hoses (Foundry Prime) on page 155. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 206: Apply Mercasol On Output Shaft Axis 2

    Equipment Article number Note Brush Required consumables Consumable Article number Note Rust preventive 3HAC034903-001 Equivalent: • Mercasol isopropyl alcohol Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 207 A Gear axis 2 B Output shaft Apply rust preventive on the out put shaft with a brush. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 208: Apply Mercasol On Output Shaft Axis 3

    The procedure describes how to remove and apply rust preventive output shaft axis 3. Action Note Put the robot in a suitable position. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 209 A Gear axis 2 B Output shaft Apply rust preventive on the out put shaft with a brush. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 210: Cleaning Activities

    Turn off all electrical power supplies to the manipulator before entering its work space. General To secure high uptime it is important that the IRB 6640 Foundry Prime is cleaned regularly. The frequency of cleaning depends on the environment in which the product works.
  • Page 211 3 Maintenance 3.7.1 Cleaning the IRB 6640 Foundry Prime Continued • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. • Do not remove any covers or other protective devices before cleaning the robot.
  • Page 212 • No other additive than water is guaranteed without prior testing or agreement with ABB. Other additives than water may have a harmful effect on the life of the robot and its components. • Recommendations given by the detergent manufacturer for the specific detergent in question must be followed.

  • Page 213: Repair

    Safety on page 19 before commencing any service work. Note If the IRB 6640 Foundry Prime is connected to power, always make sure that the IRB 6640 Foundry Prime is connected to earth before starting any repair work. For more information see: •...

  • Page 214: General Procedures

    Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 215: Mounting Instructions For Bearings

    Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 216 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 217: Mounting Instructions For Seals

    Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 218 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.

  • Page 219: Cut The Paint Or Surface On The Robot Before Replacing Parts

    Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 220 Always read the instruction in the product data sheet in the paint repair kit for Foundry Prime. Apply Mercasol on all screw heads and set screws after tightening. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 221: The Brake Release Buttons May Be Jammed After Service Work

    If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 222: Complete Robot

    Connectors at motor, axis 1 (R2.FB1, R2.MP1) Rear cover plate Earth (attachment point is placed under the cover plate) Cable harness Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 223 See Spare parts chapter. Includes: • Gaskets axes 1-5 Gasket 3HAC3438-1 Motors axes 1-5 Gasket, cover 3HAC033489-001 Motor axis 6 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 224 Cable brackets of the upper arm xx0500002293 Cable bracket, wrist unit Cable bracket, upper arm tube Cable attachment, rear Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 225 (+90º) to allow the motor 6 cover to open! Remove the cover of motor, axis 6 and discon- nect all connectors beneath. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 226 222. Disconnect connectors R1.MP and R1.SMB. Shown in the figure Location of cable harness on page 222. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 227 Disconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 from the brake re- lease unit. xx0700000104 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 228 A: Cable gland • B: Attachment screws, inside SMB recess (4 pcs) Remove the velcro strap and cable gland. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 229 Additional equipment - Foundry Note Prime on page 224 Apply rust preventive around all dismantled covers and attachment screws with a brush. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 230 Required parts on page 223 Note On Foundry Prime robots: When dismantling the cables from the motors, the gasket must be replaced. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 231 Parts: • A: Position for cover in SMB re- cess • B: Sikaflex 521FC • C: Cover Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 232 If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 233 Clean the joints that have been opened. See Cut the paint or surface on the robot before replacing parts on page 219 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 234 Note The position of axis 6 must be +90° for a cor- rect installation of the cable harness. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 235 Seal and paint the joints that have been opened. See Cut the paint or surface on the robot before replacing parts on page 219 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 236 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 237: Replacement Of Cabling, Axis 5 Motor

    • hydraulic pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 238 General calibration information is in- cluded in section Calibration informa- tion on page 439. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 239 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 240: Replacement Of Complete Arm System

    Attachment screws base M12x80, quality 12.9 Gleitmo (16 pcs) Motor, axis 1 Required equipment Equipment, etc. Art. no. Note Holder for bits 3HAC029090-001 Bits SW10 included Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 241 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 242 Manually releasing the brakes on page xx0700000351 Run the overhead crane to a position above the robot. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 243 G: Position for roundsling F, inserted through hole in the frame H: Roundsling (put in a loop around the lower arm) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 244 Disconnect the cabling in the rear of the robot base and re- move the cable support plate in- side the base. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 245 Parts: • A: Calibration plate Remove the mechanical stop pin from the frame. xx1200000668 A Mechanical stop pin Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 246 Clean the joints that have been opened. See Cut the paint or surface on the robot before replacing parts on page 219 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 247 G: Position for roundsling F, inser- ted through hole in the frame • H: Roundsling (put in a loop around the lower arm) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 248 Adjust the length of the chains as detailed in enclosed instruction or with a hoisting block. Clean the mounting surfaces with isopropan- Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 249 • A : Holes in frame for guide pins, shown from above. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 250 1-6 on page 222. Refill the gearbox with lubricating oil. Detailed in section Changing oil, axis-1 gearbox on page 170. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 251 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 252: Replacement Of Air Nipple And Hose (Foundry Prime)

    The illustration below shows the routing of the Foundry Prime air hose. xx0600003025 Hose lengths and parts See hose lengths and parts in the figure and the following tables. xx0700000449 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 253 Rubber clamp on wrist cover Motor axis 5 Motor axis 3 Motor axis 4 Bulkhead plug connector in plate at base Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 254 Items in illustration are detailed in quired equipment on page 254 Hose lengths and parts on page 252. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 255 Always install the check valve with the ar- row pointing upwards. xx1500000355 Item in illustration is detailed in Hose lengths and parts on page 252. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 256 252 quired equipment on page 254 xx0700000460 xx0700000461 xx0700000462 • A: Air hose beneath velcro strap Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 257 Upper arm housing. xx0600003046 xx0600003047 Tube shaft. Replace_hose • 1P: Lay the hose in a spiral in the tube shaft. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 258 Make sure the cable length from 5a to the nipple of axis 6 = S, see Replacement of air nipple and hose (Foundry Prime) on page 252. xx1500000356 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 259: Upper And Lower Arm

    Attachment screws (6 pcs) , turning disk xx0200000217 Turning disk (type 2) Wrist unit Oil plug, draining Oil plug, filling Attachment screws (12 pcs) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 260 Remove the turning disk. Foundry Plus: Remove old flange sealant residues and other con- tamination from the contact surfaces. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 261 Reused screws may be used, providing they are lubricated as detailed in sec- tion Screw joints on page 461 before fit- ting. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 262 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 263: Replacement Of Complete Wrist Unit

    Upper arm tube Required equipment Equipment etc. Art. no. Note Wrist unit For spare part number, Spare parts on page 487. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 264 If no previous reference values exist, and al - Calibration Pendulum. no new reference values can be created, then reference calibration is not possible. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 265 Location of wrist unit on page 263. Remove the cover of motor, axis 6 and discon- nect all connectors beneath. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 266 263. ment screws. Shown in the figure Location of wrist unit on page 263. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 267 Cables are longer in order to fit different upper arm lengths. xx0200000185 Parts: • A: Cable straps Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 268 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 269: Replacement Of Support Shaft With Bearing Axis 5

    Consumables Consumable Article number Note Rust preventive 3HAC034903-001 Mercasol Locking liquid 3HAB7116-1 Loctite 243 Sealant 1234 0011-116 Loctite 574 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 270 Pick out the cabling from motor axis 6 through the support shaft, and place it safely on the tube. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 271 Apply Loctite on surface A and Mercasol on sur- face B. xx1500001692 A Loctite 574 B Mercasol Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 272 Note Reconnect the "over pressure" air hose to axis 6 motor before tightening the cover. Note Replace gasket if damaged. xx1500001685 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 273: Replacement Of Upper Arm

    The lifting accessory is attached differently depending on whether the wrist unit is mounted on the upper arm or not. The attachment points are shown in the following figure. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 274 Required equipment Equipment Art. no. Note Sealing, axis 3 3HAC17212-1 Always use a new sealing when refitting the upper arm! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 275 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 276 Shown in the figure Location of upper arm on page 273. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 277 Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Location of upper arm on page 273. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 278 Fasten the lifting tool (chain) onto the lifting eye, Art. no. is specified in Required equip- the lifting accessory and an overhead crane. ment on page 274. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 279 Seal and paint the joints that have been opened. Cut the paint or surface on the robot before replacing parts on page 219 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 280 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 281: Replacement Of Complete Lower Arm

    Attachment for lifting equipment, balancing device Required equipment Equipment, etc. Art. no. Note Lifting accessory, lower arm 3HAC027794-001 Tool that may be rented from ABB Robot- ics. Rotation tool 3HAC17105-1 Used to rotate the motor pinion and gear if necessary, when brakes are released. Grease 3HAB3537-1 For lubrication of the shaft hole.
  • Page 282 • hydraulic pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 283 173. CAUTION The lower arm weighs 160 kg! All lifting equip- ment used must be sized accordingly! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 284 The lower arm weighs 160 kg! All lifting equip- ment used must be sized accordingly! Lift the lower arm and move it to its mounting position. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 285 General calibration information is in- cluded in section Calibration informa- tion on page 439. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 286 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 287: Frame And Base

    SMB unit DSQC633A with battery pack 3HAC16831-1 (with 2-pole battery contact) xx0700000121 SMB cover Guide pins (2 pcs) Battery cable (2-pole contact) SMB unit DSQC633A Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 288 It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 289 Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 290 Fit the SMB unit onto the guide pins. Secure the SMB unit to the pins with the nuts and washers. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 291 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 34 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 292 These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 293: Replacing The Brake Release Board

    These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 294 293. Remove the brake release board from the bracket by removing the four attachment screws. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 295 Press the push buttons 1 to 6, one at a time, to make sure that the buttons are moving freely and do not stay in a locked position. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 296 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 297: Replacement Of Spherical Roller Bearing, Balancing Device

    Location of bearing, Design 1 The bearings are located in the balancing device, as shown in the figure below. xx0900000072 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 298 Location of bearing, Design 2 The bearings are located in the balancing device, as shown in the figure below. xx0900000066 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 299 The set up of the press tool used for the process of removal and refitting of spherical bearing is described in section Dismounting and mounting tool 3HAC028920-001 on page 469. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 300 Cut the paint or surface on the robot before replacing parts on page 219 Grease the inside walls of the front ear. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 301 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 302: Replacement Of Balancing Device

    Cradle bearing Spherical roller bearing Required equipment Equipment Spare part no. Art. no. Note Balancing device See Spare parts chapter Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 303 Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 304 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 305 (M16x70) securing the piston rod shaft. Remove the retaining ring bore securing the shaft. xx0900000079 • A: Retaining ring bore Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 306 Refit one of the two retaining ring bore. Grease the cradle. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 307 Do not use Loctite on the threads of the hex socket head cap screw M16x70. xx0900000088 • A: Loctite 577 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 308 Seal and paint the joints that have been opened. See Cut the paint or surface on the robot before replacing parts on page 219 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 309 A: Mercasol - surface on the balan- cing device • B: Mercasol - on hole in the shaft • C: Mercasol - on shaft. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 310 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 311: Replacing Balancing Device (Design 2)

    The balancing device is located on rear top of the frame as shown in the figure below. xx0900000075 Balancing device Cradle bearing Spherical roller bearing Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 312 Radial sealing with dust lip 50x68x8 O-ring End cover Maintenance set - Cradle Radial sealing (Not used in Clean Room applications) Cradle bearing kit Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 313 To be used with these tools: • 3HAC028920-001 • 3HAC020902-001 Hydraulic pump, 3HAC13086-1 To be used with the hydraulic cylinder 3HAC11731-1. 80 MPa Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 314 219. Remove all equipment, if any, on or close to the balancing device. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 315 • Required equipment - tools etc. on page 313 the frame. xx0800000249 • A: Locking screw Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 316 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the ro- bot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 317 Location of parts in maintenance sets, cradle and shaft on page 312 Wipe off all residual grease inside the hole. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 318 Action Note Remove the transport protection at the loc- ation of the rear shafts. xx1000000627 • A: Transport protection Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 319 Remove the cover with the air nipple. Note Keep the cover for refitting on the new balancing unit. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 320 • A: Lubrication hole facing down • B: Cradle Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 321 The rear shaft unit to the right shows a correct fitting. xx0900000083 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 322 313 xx0900000094 CAUTION The balancing device weighs 210 kg! All lifting equipment used must be sized accord- ingly! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 323 Lock the shaft unit by fitting the retaining ring, bore. xx0900000089 Secure both M16x70 screws. Tightening torque: 300 Nm Fit new VK- covers on both sides. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 324 336 Method 2: Described in section Restoring the balancing device using distance tool on page 331. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 325 Fill the cradle bearings with 70 ml, Optimol PDO. Note The inner hole is used for lubrication. The outer hole is used for air outlet. xx0900000090 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 326 Seal and paint the joints that have been opened. See Cut the paint or surface on the robot before replacing parts on page 219 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 327: Unloading The Balancing Device Using Distance Tool

    There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property. DANGER Do not remove the distance tool from a dismounted balancing device. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 328 4 Repair 4.5.4.3 Unloading the balancing device using distance tool Continued Distance tool xx0800000478 Distance tool 3HAC030662-001 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 329 Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 330 • A . Distance tool Jog the robot lower arm backward to calib- ration position (0°). xx0800000481 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 331: Restoring The Balancing Device Using Distance Tool

    Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 332 Apply Sikaflex 521FC on the end cover gasket. of the cylinder with the four screws. xx0900000104 Use Loctite 577 on the Tightening torque 47Nm four screws. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 333: Unloading The Balancing Device Using Hydraulic Press Tool

    The press tool includes two press devices that are used to different models of the balancing device. xx0200000174 Press block Hydraulic cylinder Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 334 The article number of the balancing device may be found on a label at the rear of the balancing device. Balancing device Press device Art. no: 3HAC18100-1 xx0300000599 xx0700000475 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 335 333. Unload the hydraulic cylinder. The hydraulic cylinder may now be removed from the tool, when necessary. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 336: Restoring The Balancing Device Using A Hydraulic Press Tool

    The press tool includes two press devices that are used to different models of the balancing device. xx0200000174 Press block Hydraulic cylinder Press device Bolt, press device Moving pin with marking Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 337 Shown in the figure Press tool and hydraulic cylinder on page 336! Refit the gasket to the rear of the balancing device. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 338 The rear cover of the balancing device is a safety device for the piston rod during opera- tion! Make sure the cover is properly secured before commissioning of the robot! Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 339: Motors

    Spare part no. Note Motor axis 1 See chapter: Includes: • Spare parts • motor • pinion • o-ring Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 340 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 341 • A: Attachment screws (4 pcs) • B: Air hose (only Foundry Prime) • C: Cover • D: Motor Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 342 Grind the paint on the surface carefully to get a smoth surface. Clean the surface from contamination such as oil and dirt. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 343 Manually releasing the brakes on page 78 Connect to connector R2.MP1: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 344 Refit the motor cover with its attachment Make sure the cover is tightly sealed. screws. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 345 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 346: Replacing Motor Axis 2

    Includes: • Spare parts • motor • pinion • o-ring O-ring 21522012-430 Must be replaced when reassembling the motor. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 347 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 348 347 Drain the oil from gearbox axis 2. See section • Changing oil, axis-2 gearbox on page 173 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 349 Remove the cable gland cover at the cable Make sure the gasket is not damaged. exit. Disconnect all connectors on motor axis 2. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 350 Grind the paint edge on the surface carefully to get a smooth surface. Clean the surface from contamination such as oil and dirt. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 351 Fit two guide pins in the lower motor attachment For article number see: holes. • Required equipment - tools etc. on page 347 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 352 Apply rust protection (Mercasol) on the frame, outside the motor flange as a protection of the broken paint layers. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 353 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 354: Replacing Motor Axis 3

    • Spare parts • motor • pinion • o-ring O-ring 21522012-430 Must be replaced when reassembling motor. Gasket 3HAC3438-1 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 355 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 356 Figure showing the principal method: between the motor and the structure in or- der to avoid that the paint cracks. xx0900000121 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 357 Apply the lifting tool, motor axes 2-3 to the For art. no. see: motor. • Required equipment - tools etc. on page 355 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 358 For article number see: in the figure. • Additional equipment - Foundry Prime on page 355 xx1000000562 Part: • A: Loctite 574 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 359 Manually releasing the brakes on page 78 Connect to connector R2.MP3: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 360 • Additional equipment - Foundry as a protection of the broken paint. layers. Prime on page 355 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 361 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 362: Replacing Motor Axis 4

    • M10NB pinion • o-ring O-ring 21522012-430 Must be replaced when reassembling motor. Gasket 3HAC3438-1 Option Foundry Prime Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 363 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 364 4. • Location of motor axis 4 on page 362 Make sure the gasket is not damaged! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 365 Fit guide pins in two of the holes. For article number see: • Required equipment - tools etc. on page 363 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 366 Clean the joints that have been opened. See Cut the paint or surface on the robot before replacing parts on page 219 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 367 Secure the motor with its attachment M8x25 screws. 4 pcs Tightening torque: 24 Nm. Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 368 Only if gearbox has been drained. See section • Changing oil, axis-4 gearbox on Refill the gearbox with oil. page 179 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 369 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 370: Replacing Motor Axis 5

    The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit. See figure! xx0200000204 Motor axis 5 (inside upper arm tube) Upper arm tube Wrist unit Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 371 See Circuit diagram. Additional equipment - Foundry Prime Equipment Art. no. Note Rust preventive 3HAC034903-001 Mercasol Sikaflex 521FC 3HAC026759-001 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 372 Replacement of complete wrist unit on page 263 Place the wrist safely on a workbench, in a fixture or similar. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 373 For article number see: tachment screws of motor axis 5. • Required equipment - tools etc. on page 371 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 374 Grind the paint edge on the surface carefully to get a smooth surface. Clean the surface from contamination such as oil and dirt. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 375 This is necessary in order to achieve an even friction torque when fitting the pinion. Place the motor and the pinion in a press fixture. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 376 For article number see: • Additional equipment - Foundry Prime on page 371 xx1000000623 Part: • A: Loctite 574 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 377 Fit a new gasket on the cable gland. For article number see: • Required parts on page 371 Refit the separate cable of motor axis 5. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 378 Calibration is detailed in a separate calib- ration manual enclosed with the calibra- tion tools. General calibration information is included in section Calibration information on page 439. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 379: Replacing Motor Axis 6

    Gasket 3HAC048560-001 Must be replaced when replacing mo- tor. Gasket, cover 3HAC033489-001 Must be replaced when opening cover. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 380 Location of motor axis 6 on page 379 enables the motor to be replaced without draining the oil in gearbox axis 6. This will save time. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 381 D: Rear motor cover • E: Gasket Remove the rear motor cover. Keep the old rear motor cover with the air nipple. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 382 A: Tilthouse • B: Motor axis 6 • C: Attachment screws (4 pcs) Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 383 Fit a new gasket on the motor by removing the protection strip and paste it on the new motor. xx1000000625 Part: • A: Gasket Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 384 Fit guide pins in two of the holes for the For article number see: motors attachment screws. • Required equipment - tools etc. on page 380 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 385 Reconnect all connectors on motor axis 6. Refit the cover on top of the motor. Make sure the cover is tightly sealed. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 386 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 387: Gearboxes

    Refitting protection pipe and cable guide - Foundry Prime on page 401 • Refitting the concluding parts - Foundry Prime on page 404 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 388 Radial sealing 3HAC11581-4 Hex socket head cap 3HAB3409-86 M16x60 screw Gleitmo 12.9 (12 pcs) Washer 3HAA1001-186 17x215x3 (12 pcs) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 389 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 390 Cutaway view of gearbox axis 1 xx1000000329 Cable guide Surfaces to be lubricated with grease Radial sealing O-ring (3 pcs) Protection pipe axis 1 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 391 The complete gearbox unit and base weighs 241 kg together! (Base: 133 kg, gearbox unit: 108 kg.) All lifting equipment used must be sized accordingly! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 392 Remove the protection pipe axis 1 from the See the figure in: removed gearbox. • Cutaway view of gearbox axis 1 on page 390 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 393 Apply Mercasol on the surface outside the See the figure above. guidance edge. Note Make sure there is no Mercasol on the joint surface. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 394 Make sure the o-ring is fitted to the gearbox as shown in the figure to the right. Lightly lubricate the o-ring with grease. xx1200000674 A O-ring Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 395 Apply Mercasol on surfaces on the gearbox unit, as described in the figure. xx1000000333 • A: Mercasol • B: Gearbox Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 396 Note The two M6x50 screws shall be replaced by two stainless M6x16 when the sealing ring has been installed. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 397 Note Make sure that Mercasol is not used on washers and threads of attachment screws before tightening! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 398 Fit the lifting equipment on the complete arm system as described in section Replace- ment of complete arm system on page 240. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 399 Lower the arm system into its place and secure the arm system to the base with its attachment screws. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 400 Mercasol shall be applied after the attach- ment screws has been tightened! xx1000000363 • A: Attachment screw • B: Mercasol Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 401 • Required equipment on page 388 Use a plastic mallet. xx1000000366 • A: Plastic mallet • B: Press tool Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 402 • A: Groove • B: Correct position of protection pipe • C: Protection pipe • D: Center tube Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 403 • A: Groove • B: Cable guide • C: Protection pipe • D: Center tube Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 404 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 405: Replacing Gearbox Axis 2

    Attachment screws, M16x50 quality 12.9 Gleitmo (20 pcs) Attachment screws, M12x60 quality 12.9 Gleitmo (32 pcs) Gearbox axis 2 Motor axis 2 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 406 See refer- to the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 407 2) on page 311 Jog the robot to the following position: • Axis 2 = -60° • Axis 3 = +60° xx0700000351 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 408 F: Roundsling (put in a loop around the wrist on the inside) • G: Roundsling (put in a loop around the lower arm) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 409 Release the brakes of axis 2 to let the weight of the arm system settle in the lifting accessories. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 410 Cut the paint or surface on the robot before replacing parts on page 219. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 411 • A: Lifting tool Remove the gearbox. Use two M12 screws to push out the gear- box, if necessary. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 412 Apply Mercasol on the machined surface. See figure above Note Make sure there is no Mercasol on the joint surface! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 413 Check that the spare part is painted as shown in the figure. xx1000000380 • A: Unpainted surfaces • B: Painted surfaces Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 414 Mercasol. xx1000000380 Parts: • A: Mercasol (on unpainted surface) • B: Gearbox axis 2 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 415 • Required equipment on page 406 roundsling in an overhead crane or similair. xx1000000378 Part: • A: Lifting tool Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 416 B: Set screw (2 pcs opposite each other) Apply Mercasol on all screw heads and set See figure above. screws after tightening. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 417 • Required equipment on page 406 Apply Mercasol on all screw heads of the attachment screws after tightening them. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 418 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 419: Replacing Gearbox Axis 3

    Refitting gearbox axis 3 on the upper arm on page 427 • Refitting the upper arm on page 428 • Concluding refitting procedure on page 429 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 420 Required equipment Equipment Spare part no. Art no. Note Gearbox See Spare parts Includes: chapter • Gearbox • O-ring 3HAB3772-68 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 421 See refer- quired. ences to these proced- ures in the step-by- step instructions be- low. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 422 When removing motor axis 3, the brake on axis 3 i released. Make sure the upper arm is secured and disabled from moving. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 423 Fit the lifting eye to the gearbox. Remove the gearbox with guidance from the guide pins. Use an overhead crane or simil- Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 424 B: Lower arm • C: Joint surface (3x) Note Make sure that there is no Mercasol on the joint surfaces. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 425 A: Joint surface • Surface for o-ring Clean the surface for the o-ring in the upper See figure above. arm housing. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 426 Apply some grease on the o-ring in order to make it stay in the groove during assembly. xx0200000173 Part: • A: O-ring, gearbox axis 3 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 427 Turn off all: • electric power supply • hydraulic pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 428 Fill the hole for the slotted spring pin with Sikaflex 521FC. xx1000000439 Part: • A: Hole for slotted spring pin Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 429 General calibration information is included in section Calibration information on page 439. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 430 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 431: Replacing Gearbox Axis 6

    Attachment screws, M8x40 with washers (18 pcs) Oil plug, draining Oil plug, filling O-ring (not shown in the figure) Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 432 Required equipment - Foundry Prime Equipment Spare part no. Art. no. Note Rust preventive 3HAC034903-001 Mercasol Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 433 Remove the gearbox by unscrewing its 18 See section attachment screws. • Location of gearbox axis 6 on page 431 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 434 Make sure the o-ring is fitted to the rear of the gearbox. Lubricate the o-ring with grease. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 435 431 Tightening torque: 30 Nm. M8x40 quality 12.9 Gleitmo (18 pcs) Note Use new attachment screws and washers! Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 436 Performing a leak-down test on page 214 Refill gearbox axis 6 with oil. See section • Changing oil, axis-6 gearbox on page 185 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 437 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 438 This page is intentionally left blank...

  • Page 439: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.

  • Page 440: Calibration Methods

    Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N ©...
  • Page 441 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum, which describes the method and the different routines further. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 442: Synchronization Marks And Synchronization Position For Axes

    Calibration mark axis 4 Calibration mark axis 5 Calibration mark axis 6 Calibration mark axis 5, IRB 6640ID Calibration mark axis 6, IRB 6640ID Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 443: Calibration Movement Directions For All Axes

    Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 444: Updating Revolution Counters

    (try both directions, if needed). Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 445 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 446 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 447. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 447: Checking The Synchronization Position

    If they do not, up- ization position for axes on page 442 date the revolution counters. Updating revolution counters on page 444. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 448 This page is intentionally left blank...

  • Page 449: Decommissioning

    These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 450: Environmental Information

    Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 451 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 452: Scrapping Of Robot

    • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 453: Decommissioning Of Balancing Device

    The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 454 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft. figure. The measurements shown below are maxim- um values! xx0700000391 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 455 Inner spring: cut at least four coils! Double-check the number of coils cut and make sure all the tension in the springs are removed. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 456 This page is intentionally left blank...

  • Page 457: Reference Information

    7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 458: Applicable Standards

    Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 459 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 460: Unit Conversion

    2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 461: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
  • Page 462 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 463 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 464: Weight Specifications

    All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

  • Page 465: Standard Tools

    Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 466: Special Tools

    3HAC020999-001 Guide pins M12 x 130 3HAC022637-001 Guide pins M12 x 150 3HAC13056-2 Guide pins M12 x 200 3HAC13056-3 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 467 Levelmeter 2000 kit 6369901-347 Includes one sensor. Measuring pin 3HAC13908-5 Sensor fixture 68080011-GM Sensor plate 3HAC0392-1 Sync. adapter 3HAC13908-1 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 468 • Couplings and adapters • Pump (manual) with hose and coupling • Graduated measuring glass • Oil gun • User instructions. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 469: Dismounting And Mounting Tool 3Hac028920-001

    Removal rear shafts Design 1 and 2 on page 481 • Refitting rear shafts Design 1 on page 482 • Refitting rear shafts Design 2 on page 484 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 470 Tool description xx0900000024 Item Mark Description Hydraulic cylinder not included in tool 3HAC028920-001 (ordered separ- ately). Press tool D=103 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 471 The following configuration is used for removal of the front shaft Design 1 and 2. In the figure only Design 1 is shown. Configuration: • • • • xx0900000026 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 472 M16. 4) Assemble the nut M16. xx0900000027 Alternative con- figuration: • • • • • xx0900000028 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 473 The following configuration is used for refitting of the front shaft Design 1 and 2. Configuration: • • • xx0900000063 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 474 7 Reference information 7.8 Dismounting and mounting tool 3HAC028920-001 Continued xx0900000091 xx0900000065 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 475 The following configuration is used for removal of the front bearing Design 1. Configuration: • • • • • xx0900000031 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 476 Slide hammer / Distance. 5) Assemble the nut M16. xx0900000032 Alternative con- figuration • • • • • xx0900000033 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 477 The following configuration is used for refitting of the front bearing and sealing Design 1 Configuration: • • • • • xx0900000036 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 478 The following configuration is used for removal of the front bearing Design 2. Configuration: • • • • • xx0900000038 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 479 Slide hammer / Distance (C). 5) Assemble the xx0900000039 nut M16 (8). Alternative config- uration: • • • • • xx0900000040 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 480 The following configuration is used for refitting of the front bearing with sealing Design 2. Configuration: • • • • • xx0900000042 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 481 The following configuration is used for removal of the rear shafts Design 1 and 2. Configuration: • • • • • • xx0900000044 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 482 The following configuration is used for refitting of the rear shafts Design 1. Configuration: • • • • • xx0900000047 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 483 Press tool D=110 (G). 4) Assemble the Slide hammer / Distance (C). 5) Assemble the Nut M16 (8). xx0900000060 xx0900000048 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 484 3) Assemble the Press tool D=110 (G). 4) Assemble the Slide hammer / Distance (C). 5) Assemble the Nut M16 (8) xx0900000061 xx0900000050 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.

  • Page 485: Lifting Accessories And Lifting Instructions

    This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 486 This page is intentionally left blank...

  • Page 487: Spare Parts

    Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 488 This page is intentionally left blank...

  • Page 489: Circuit Diagrams

    3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 490 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 491 168 disposal, 450 grease changing oil disposal, 450 axis 1, 170 guide pins, base plate, 81 cleaners approved, 212 requirements, 212 hanging Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 492 67 working range axis 1, 108 MoveAbsJ instruction, 447 working range axis 2, 110 working range axis 3, 112 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 493 188, 287 wrist unit, replacement, 263 replacing, 188, 287 special tools, 466 speed adjusting, 117 replacing, 206, 208 stability, 69 Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 494 Index checking, 447 zero position Product manual - IRB 6640 Foundry Prime 3HAC040586-001 Revision: N © Copyright 2011-2018 ABB. All rights reserved.
  • Page 496 Robotics and Motion No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2011-2018 ABB. All rights reserved.

Table of Contents