Page 1 ROBOTICS Product manual IRB 6620...
Page 2 Trace back information: Workspace R18-1 version a9 Checked in 2018-03-22 Skribenta version 5.2.025...
Page 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
Axes with restricted working range ............. 2.6.2 Mechanically restricting the working range of axis 1 ........2.6.3 Mechanically restricting the working range of axis 3 ........Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 6 Replacement of the upper arm ..............4.4.4 Replacement of lower arm ................ Frame and base ....................4.5.1 Replacement of SMB unit ................. 4.5.2 Replacing the brake release board ............. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 7 Replacement of motor axis 2 ..............4.6.3 Replacement of motor, axis 3 ..............4.6.4 Replacement of motor, axis 4 ..............4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX ........... 4.6.6 Replacement of motor, axis 6 ..............Gearboxes ....................... 4.7.1 Replacement gearbox axis 1 ..............
Page 8 This page is intentionally left blank...
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 Reference Document ID Product specification - IRB 6620 3HAC025861-001 Product manual, spare parts - IRB 6620 3HAC049109-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Operating manual - General safety information 3HAC031045-001 Product manual - IRC5 3HAC021313-001 IRC5 with main computer DSQC 639.
Page 11 122. • Corrected item number reference in part list, see Spare parts - Upper arm in Product manual, spare parts - IRB 6620. • Circuit diagrams are not included in this document but delivered as separate files. See Circuit diagram on page 353.
Page 12 New wrist cover and improved sealing on arm house cover, and more. • Minor corrections. This revision includes the following updates: • Minor corrections. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 13 Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previously created reference calibra- tion values. • Information about myABB Business Portal added. • Added Nickel in Environmental information. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 17: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
Page 18 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 19 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 20: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 21: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 22: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 23: Make Sure That The Main Power Has Been Switched Off
Wait for 5 minutes to let the capacitors discharge after the power has been switched off. DANGER Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 24: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 25 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 26: Moving Robots Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 27: First Test Run May Cause Injury Or Damage
If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 29: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 30: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 31 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 32: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 33: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 34: Safety Risks Related To Pneumatic/Hydraulic Systems
Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 35: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 36: Safety Risks During Handling Of Batteries
Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 37: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 38 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 39: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 40 Significance NOTE 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 41: Safety Symbols On Product Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 42 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 43 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 44 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 45 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 46 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 47: Installation And Commissioning
Safety on page 17 before performing any installation work. Note If the IRB 6620 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5...
Page 48: Robot Transportation Precautions
Pre-installation procedure on page 57 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 6620 3HAC027151-001 Revision: T ©...
Page 49 Always read and follow the instructions in section Securing the robot with a transport support on page 54 • 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 50 2.2 Robot transportation precautions Continued IRB 6620 xx0800000036 Transport Support Hexagon socket head cap screw M10x50 Threaded bar M10x280 Nut M10 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 51 Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 6620 xx0800000041 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 52 2.2 Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 6620 xx0800000039 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 53 2 Installation and commissioning 2.2 Robot transportation precautions Continued IRB 6620 xx0800000038 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 54: Securing The Robot With A Transport Support
Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 55 See attachment point for the specific ro- (A) in figure. bot in the section Transport position with a transport support on page Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 56 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 79 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 57: 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 58 These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 59 Maximum tilt 15° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T...
Page 60 Protection class Manipulator, protection type Standard IP 54 Manipulator, protection type Foundry Plus IP 67 The upper arm, including the wrist, has protection class IP 67. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 61: Working Range And Type Of Motion
Floor mounted The illustration below shows the unrestricted working range when the robot is floor mounted: 8 58 1473 2204 xx0600002906 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 62 2.4.2 Working range and type of motion Continued Suspended mounted The illustration below shows the unrestricted working range when the robot is mounted suspended: 2204 1473 xx0600002907 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 63 15° angle: 1019 1171 2369 xx0600002908 Note! Maximum tilt angle is 15° Intersection between base and axis 1 center Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 64 + 300° to - 300° default Max. ±96 revolutions ¹ ¹ The default working range can be extended by changing parameter values in the software. OptionAdvanced Motion is required. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 65: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx0600002935 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 66: On-Site Installation
If the robot is dressed, this must be taken into consideration when the robot is be- ing lifted. xx0600002935 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 67 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 68 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 69: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 70 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 71 Continued Action Note Remove the attachment bolts securing the robot to the foundation. CAUTION The IRB 6620 robot weighs 900 kg. All lifting accessories used must be sized accordingly! Carefully lift the robot. WARNING Personnel must not, under any circum-...
Page 72: Lifting The Robot With Lifting And Turning Tool
The lifting and turning tool 3HAC025792-001is used for lifting and turning of the IRB 6620. xx0900000325 Upper lifting beam Chains Lifting eye Lower lifting beam Lifting hold (Left and Right) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 73 Lifting position xx0900000330 Action Note Jog the robot axis to a posi- Lifting position according to figure. tion suitable for lifting Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 74 Lifting eye upper beam Attachment bolts in robot base Distribution beam Attachment bolts for distribution beam Lifting chains Chain block lifting eye Upper beam Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 75 Note Use a suitable chain block for minimum lifting weight 500 kg and with chain length minimum 3 m. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 76 350 mm. Turn the robot using the chain block. If the robot is to be moved to the installation location, use a forklift. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 77: Lifting Robot With Roundslings
2, in order not to dam- age the harness! CAUTION The IRB 6620 robot weighs 900 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T ©...
Page 78 Roundsling upper arm, 2 m. Roundsling robot, 2.5 m (4 pcs). Lifting eye, M20 (4 pcs) Holes for lifting eyes in the robotbase. (Rear holes) Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 79: Manually Releasing The Brakes
Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 80 Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 81: Lifting The Base Plate
Fit lifting slings to the eyes and to the lifting accessory. CAUTION Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 82: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 83 2 Installation and commissioning 2.5.6 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 84 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 85 Base plate 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 86 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 87: Orienting And Securing The Robot
M24 x 100 Quality: Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 88 Note 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 89 2.5.7 Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. R400 xx0600002932 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 90 2 Installation and commissioning 2.5.7 Orienting and securing the robot Continued Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0600002934 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 91: Setting The System Parameters For A Suspended Or Tilted Robot
The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 92 Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Tilted mounting 15° 0.261799 Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 93 Examples of mounting angles tilted around the Y axis (Gravity Beta) xx0600003144 Floor mounted Tilted mounting, mounting angle 15°. Suspended mounting, mounting angle 180°. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 94 90° (Wall) 1.570796 -90° (Wall) -1.570796 Note For suspended robots (180°), it is recommended to use Gravity Beta instead of Gravity Alpha. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 95 The system parameters are described in Technical reference manual - System parameters. The system parameters are redefined in the Configuration Editor, in RobotStudio or on the FlexPendant. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 96: Fitting Equipment On Robot
Make sure not to damage the robot cabling on the lower arm when fitting extra equipment. Always use appropriate attachment screws! xx0600002940 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 97 2 Installation and commissioning 2.5.9 Fitting equipment on robot Continued xx0600002944 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 98 Illustration, fitting of extra equipment on upper arm The illustrations below shows the mounting holes available for fitting extra equipment on the upper arm. xx0600002941 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 99 2 Installation and commissioning 2.5.9 Fitting equipment on robot Continued xx0600002945 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 100 Illustration, fitting of extra equipment on frame The mounting holes available for fitting extra equipment on the frame are shown below. xx0600002947 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 101 2 Installation and commissioning 2.5.9 Fitting equipment on robot Continued xx0600002950 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 102 Turning disk for robot version IRB6620 - 150/2.2. Use every other of the bolt holes for six attachment bolts, as numbered in the figure. Turning disk type 1 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 103 2 Installation and commissioning 2.5.9 Fitting equipment on robot Continued xx0200000197 Turning disk (type 2) for robot version IRB 6620 Foundry Plus. Fastener quality When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9.
Page 104: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 105: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 106: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 107: Mechanically Restricting The Working Range Of Axis
Movable mechanical stop 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 108 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 109: Mechanically Restricting The Working Range Of Axis 3
• document for Mech stop pin, 3HAC025409-001. Standard toolkit Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 110 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 111: Foundry Plus Cable Guard (Option)
Separate instructions for IRB 140, 4600, 1600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found on the DVD delivered with the Cable guard, article number 3HAC035933-001. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 112: Electrical Connections
Robot cable, power: 7 m 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 113 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1500001603 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 114: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 115: Maintenance
Safety on page 17 before performing any service work. Note If the IRB 6620 is connected to power, always make sure that the IRB 6620 is connected to protective earth before starting any maintenance work. For more information see: •...
Page 116: Maintenance Schedule And Expected Component Life
40000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.
Page 117: Maintenance Schedule
The following table specifies the required maintenance activities and intervals. Maintenance activity Equipment Interval Cleaning Robot Cleaning the IRB 6620 on page 173 Inspection Oil level in axis-1 gearbox Every 12 months. Inspection Oil level in axis-2 gearbox Every 12 months.
Page 118 Maintenance activity Equipment Interval Note Inspection Signal lamp Every: 12 months Inspection Mechanical stop axis 1 Every: and 3 12 months Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 119: 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 120: Inspection Activities
Before proceeding, please read the safety informa- tion in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 121 Further information about how to fill with oil is found in section Changing oil, axis-1 gearbox on page 151. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 122: Inspecting The Oil Level In Axis-2 Gearbox
The following figure shows suspended mounted robot. The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0600002960 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 123 Open the oil plug, filling and inspection. Shown in the figure Location of gear- box on floor mounted robot on page 122. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 124 149. Filling of oil is detailed further in the section Filling, oil on page 155. Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 125: Inspecting The Oil Level In Axis-3 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 126 Further information about how to fill the oil may be found in the section Filling, oil on page 159. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 127: Inspecting The Oil Level In Axis-4 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 128 Further information about how to fill the oil may be found in the section Filling, oil on page 161. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 129: Inspecting The Oil Level In Axis-5 Gearbox
Move the robot upper arm to a horizontal position. Turn the wrist unit in a way that both oil plugs are facing upwards. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 130 Further information about how to fill the oil may be found in the section Filling, oil, axis 5 on page 164. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 131: Inspecting The Oil Level In Axis-6 Gearbox
Move axes 3 and 5 to a horizontal position, and make sure that the oil plug, filling and inspection is facing upwards. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 132 This will avoid surface tension from stopping air to enter into the gearbox. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 133 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 134: Inspecting, Cable Harness
SMB/BU box Top cover, connection box Connection plate, base Connector R1.SMB Connector R1.MP Metal clamps Cable harness Cable guide (cut away view) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 135 • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 136 Detailed in section: is detected! Replacement of cable harness, lower end (axes 1-2) on page 185 Replacement of cable harness, upper end on page 192 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 137: Inspecting The Information Labels
Warning sign, symbol of a flash (located on motor cover) (5 pcs) Warning label concerning brake release Instruction label concerning lifting Serial no. from rating label Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 138 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare part lists on page 351. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 139: Inspecting The Axis-1 Mechanical Stop Pin
The axis-1 mechanical stop is located as shown in the figure. xx0600002972 Mechanical stop pin, axis 1 Fixed mechanical stop Required equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 140 If the mechanical stop pin is bent or damaged, it must be replaced. Note The expected life of gearboxes can be reduced after collision with the mechanical stop. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 141: Inspecting The Additional Mechanical Stops
Additional mechanical stops are not provided for axis 2. 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 142 Attachment screw and washer • Document for mechanical stop pin Standard toolkit Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 143 Article number is specified in be replaced. Required equipment on page 142. Correct attachment screws: • Axis 1: M12 x 40, quality 12.9. • Axis 3: M6 x 16 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 144: Inspecting The Damper On Axes 2-5
Damper axes 2-3 3HAC12320-1 Damper axis 5 3HAC024541-001 Standard toolkit 3HAC15571-1 Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 145 If any damage is detected, the damper must be re- Art. no. is specified in Required placed with a new one! equipment on page 144. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 146: Inspecting, Signal Lamp
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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 147 • Checking cable connections. • Measuring the voltage in connectors motor axis 3 (=24V). • Checking the cabling. Replace cabling if a fault is detected. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 148: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 149: Replacement/Changing Activities
Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
Page 150 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 151: Changing Oil, Axis-1 Gearbox
Content is defined in section ment Special tools on page 347. Standard toolkit Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 152 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 153 120. on page 149. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 154: Changing Oil, Axis-2 Gearbox
Content is defined in section ment Special tools on page 347. Standard toolkit Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 155 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 156 122. page 149. Note Don´t mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 157: Changing Oil, Axis-3 Gearbox
Special tools on page 347. Oil collecting vessel Capacity: 3,000 ml. Standard toolkit Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 158 Draining is time-consuming. Elapsed time or grease) on page varies depending on the temperature of the oil. Refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 159 125. on page 149. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 160: Changing Oil, Axis-4 Gearbox
Art. no. for the kit is specified in Required equipment on page 160. Action Note Run the upper arm -45° from the calibration position. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 161 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 162 127. amount is detailed in Type and amount of oil in gearboxes on page 149. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 163: Changing Oil, Axis-5 Gearbox
Required equipment on page 163. Action Note Move the robot to its calibration position. This puts the oil plug draing in the right position. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 164 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 165 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 149. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 166: Changing Oil, Axis-6 Gearbox
Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. The figure shows gearbox axis 6 for IRB 6620 Foundry Plus. xx0600002964 Gearbox axis 6 Oil plug, filling...
Page 167 The correct oil level is detailed in section Inspect- amount of oil in gearboxes on ing the oil level in axis-6 gearbox on page 131. page 149. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 168 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 131. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 169: Replacing The Smb Battery
The SMB battery (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below. xx0600002982 Attachment screws SMB/BU unit (complete) Velcro strap Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 170 Equipment, etc. Spare part no. Note Battery pack For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part approved equivalent. lists on page 351 Standard toolkit Content is defined in section...
Page 171 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 169. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
Page 172 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 173: Cleaning Activities
General To secure high uptime it is important that the IRB 6620 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 6620.
Page 174 3 Maintenance 3.5.1 Cleaning the IRB 6620 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 175 Remove waste material, such as sand, dust and chips, if it prevents cable movement. • Clean the cables if they have a crusty surface, for example from dry release agents. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 176 This page is intentionally left blank...
Page 177: Repair
Make sure to read through the chapter Safety on page 17 before commencing any service work. Note If the IRB 6620 is connected to power, always make sure that the IRB 6620 is connected to earth before starting any repair work. For more information see: •...
Page 178: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 179: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 180 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 181: Mounting Instructions For Seals
Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 182 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 183: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 184: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 185: Complete Robot
The cable harness for axes 1-2 is run throughout the base and frame as shown in the figure below. xx0600002970 SMB/BU unit Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 186 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 187 Shown in the figure Location of cable harness, axes tion box from the robot by re- 1-2 on page 185. moving its attachment screws. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 188 Remove the metal clamps on Shown in the figure Location of cable harness, axes the frame, securing the cable 1-2 on page 185. harness. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 189 R1.MP and R1.SMB at the con- Shown in the figure Location of cable harness, axes nection plate, base. 1-2 on page 185. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 190 185. ness. Refit the top cover, connection Shown in the figure Location of cable harness, axes box. 1-2 on page 185. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 191 These are fur- ther detailed in the section First test run may cause injury or damage on page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 192: Replacement Of Cable Harness, Upper End
Attachment screws, metal clamp lower arm, M6x16 quality 8.8 (2+2 pcs) Metal clamp, armhouse Attachment screws, metal clamp armhouse, M6x16 quality 8.8 (2 pcs) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 193 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 194 Make sure not to lose the washers placed xx0600003024 in the holes of the foundry gasket. • A : Cover, wrist unit xx1400002580 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 195 A : Cable holder • B : Attachment screws M6x16, 8.8 (2 pcs) • C : Attachment screw M4x12, 8- A2F (securing the carrier) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 196 Use caution and pull out the cable harness of the upper arm. Tie the connectors into a bundle, to avoid damaging them during further removal. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 197 Reconnect the motor cables axis 6 R2.MP6 Shown in the figure Location of cable and R2.FB6. harness on page 192 Refit cover motor, axis 6. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 198 A : Cable harness • B : Motor, axis 5 • C : Attachment screws M6x16, 8.8 (2 pcs) • D : Metal clamp Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 199 Make sure the wrist cover gasket and the small gasket fitted in the recess of the wrist cover are undamaged. Replace if damaged. xx1400002579 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 200 Fit the Foundry Plus cover on the adapter ring. xx1400002582 Make sure the gasket on the adapter ring is undamaged. Replace if damaged. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 201 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 202: Replacement Of Complete Arm System
Attachment screws base M12x80, quality 12.9 Gleitmo (16 pcs) Required equipment Equipment, etc. Art. no. Note Lifting accessory, robot 3HAC026597-001 Instruction 3HAC026600-002 is en- closed! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 203 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 204 Manually releasing the brakes on page xx0600003125 Run the overhead crane to a position above the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 205 (axes 1-2) on page 185. gearbox. Remove the motor, axis 1. Detailed in section Replacement of motor, axis 1 on page 242. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 206 E : Roundsling (used to transfer the load of the frame) Remove the mechanical stop pin from the frame. xx1200000668 A Mechanical stop pin Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 207 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 208 • A : Lifting tool • B : Roundsling • C : Lifting chain • D : Hoisting block Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 209 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 210 B Hole for attachment screw. Lubricate the outer surface of the gearbox for easier mating of the gearbox and arm system. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 211 (axes 1-2) on page 185. Refill the gearbox with lubricating oil. Detailed in section Changing oil, axis-1 gearbox on page 151. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 212 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 213: Upper And Lower Arm
Location of turning disk The turning disk is located in the front of the wrist housing as shown in the figure below. The figure shows the turning disk on an IRB 6620 Foundry Plus/IRB 6620LX. xx0600003082 Turning disk Wrist unit...
Page 214 213. 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 215 See section • Changing oil, axis-6 gearbox on page 166 Refit any equipment removed during disas- sembly to the turning disk. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 216 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 217: Replacement Of Wrist Unit
351. Wrist unit, insulated Spare part lists on page 351. Retrofit set Foundry Plus, Spare part lists wrist on page 351. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 218 Move the robot to a suitable position for removal of the wrist unit. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 219 Action Note Secure the wrist unit with a roundsling in an over- head crane and lift it to its mounting position. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 220 Axis Calibration is described in Calibrating with Axis Calibration method on page 319. General calibration information is included in section Calibration on page 305. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 221 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 222: Replacement Of The Upper Arm
Instruction 3HAC026600- 002 is enclosed. Lifting chain Roundsling Guiding pins Always use in pairs. Hoisting block Grease 3HAB3537-1 Used to lubricate o-rings. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 223 The procedure below details how to remove the upper arm. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 224 D : Hoisting block Remove the cable harness, axes 3-6. Detailed in the section Replacement of cable harness, upper end on page 192. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 225 The complete upper arm (incl. gearbox axis 3) weighs 282 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 226 178. Refit the cable harness, axes 3-6. Detailed in section Replacement of cable harness, upper end on page 192. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 227 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 228: Replacement Of Lower Arm
Attachment screws, M16x50 quality 12.9 Gleitmo (16 pcs) xx0600003059 Lower arm Hole in lower arm Gearbox, axis 2 Attachment screws, M16x50 quality 12.9 Gleitmo (16 pcs) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 229 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 230 Detailed in the section Replacement of the upper arm on page 222. Secure the lower arm with a roundsling in an overhead crane. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 231 Calib- rating with Axis Calibration method on page 319. General calibration information is in- cluded in section Calibration on page 305. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 232 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 233: Frame And Base
Serial measurement unit (SMB), RMU 101 Brake release unit (BU), DSQC 1050 Push button guard Cover, push button guard Gasket (Foundry Plus) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 234 Clean cover from metal residues before open- ing. Metal residues can cause shortage on the boards which can result in hazardous failures. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 235 A: Hexagon nut, M5 • B: Tooth lock washer, 6.4 fzb • C: Hexagon screw, M5x12 quality 8.8 Pull the SMB unit out carefully. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 236 Location of SMB the attachment screws. unit on page 233. Update the revolution counters! Detailed in section Updating revolution counters on page 313. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 237 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 238: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 239 Location of the brake release unit is shown in the figure Location of brake release board on page 238. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 240 Refit the push button guard to the SMB cover. Shown in the figure Location of brake release board on page 238. Refit the cover, push button guard. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 241 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 242: Motors
The motor axis 1 is located as shown in the figure below. xx0600003037 Motor, axis 1 Motor attachment screws and washers Cable gland Cover Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 243 See references to quired. these procedures in the step-by-step in- structions below. Circuit diagram See chapter Circuit dia- gram on page 353. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 244 Remove the cover for connector access on top of Shown in the figure Location of the motor by unscrewing its four attachment screws. motor on page 242. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 245 243. ring with grease. CAUTION The motor weighs 25 kg! All lifting equipment used must be sized accordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 246 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 247 For guiding the motor. Guides are to be used in pairs! Lifting tool, motor ax 3HAC026061-001 Extension bar, 300 3HAC12342-1 mm for bits 1/2" Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 248 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 249 Changing oil, axis-2 gear- box on page 154. Remove the cover on top of the mo- tor by unscrewing its four attach- ment screws. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 250 Remove the motor by gently lifting it straight out and place it on a se- cure surface. Disconnect the brake release voltage. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 251 Location of motor on page 247. Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 252 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 253: Replacement Of Motor, Axis 3
Used to rotate the motor pin- ion when mating it to the gear when brakes are released with 24 VDC power supply. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 254 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 255 The motor axis 3 can now be replaced without securing the armsys- tem in an overhead crane. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 256 Remove the motor by gently lifting Make sure the motor pinion is not damaged! it straight out and disconnect the brake release voltage. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 257 In order to release the brake, connect the 24 VDC Connect to connector R2.MP3 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 258 Cal- ibrating with Axis Calibration meth- od on page 319. General calibration information is included in section Calibration on page 305. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 259 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 260: Replacement Of Motor, Axis 4
24 VDC, max. 1,5 A For releasing the brakes. Standard toolkit Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 261 The procedure below details how to remove the motor, axis 4. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 262 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 263 Detailed in the section Performing a leak- been drained. down test on page 178. Refill the gearbox with oil if drained. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 264 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 265: Replacement Of Motor, Axis 5 , Irb 6620/6620Lx
4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Location of motor The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below.
Page 266 4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Continued Equipment, etc. Art. no. Note Removal tool, motor M10x 3HAC14972-1 Always use the removal tools in pairs! Extension bar 300 mm for 3HAC12342-1 bits 1/2" Guide pins M8 x 100 3HAC15520-1 For guiding the motor.
Page 267 4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Continued Removal, motor, axis 5 The procedure below details how to remove motor, axis 5. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.
Page 268 4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Continued Action Note If required, press the motor out of position by fit- Art. no. is specified in Required ting removal tool, motor, M10 to the motor attach- equipment on page 265.
Page 269 4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Continued Action Note Foundry Plus Make sure that the gasket is undamaged. Also the small gasket fitted in the cover recess. Replace if damaged. xx1400002579 Foundry Plus Make sure the washers are fitted in the gasket holes.
Page 270: Replacement Of Motor, Axis 6
Must be replaced when reas- sembling motor! Gasket 3HAC048560-001 Must be replaced when repla- cing motor Gasket, cover 3HAC033489-001 Must be replaced when opening cover. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 271 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 272 In order to release the brake, connect the 24 VDC Connect to connector R3.MP6 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 273 In order to release the brake, connect the 24 Connect to connector R3.MP6 VDC power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 274 Calib- rating with Axis Calibration method on page 319. General calibration information is in- cluded in section Calibration on page 305. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 275 • E: Gasket Continue to remove the motor unit, according to step 6 and forwards in Removal, motor on page 272. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 276 Apply Loctite 574 flange sealant on the contact surface. xx1400000992 Apply grease on the o-ring on the motor. Continue to refit the new motor according to section, Refitting, motor on page 273. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 277: Gearboxes
Includes: on page 351. • gearbox • o-ring O-ring 3HAB3772-93 Replace only when dam- aged. 380.6x3.53 O-ring (3 pcs) 3HAB3772-97 23x3.6 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 278 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 279 Art. no. is specified in Required equipment allow fitting the support, base and gear axis on page 277. 1 on each side of the base. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 280 1, this should axis 1 is detailed in section Removal on be done first. page 279. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 281 Lift the gearbox on to the guide pins and lower it carefully to its mounting position. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 282 CAUTION The complete arm system weighs 590 kg! All lifting equipment used must be sized ac- cordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 283 • A : Lifting tool • B : Roundsling • C : Lifting sling • D : Hoisting block Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 284 • A: Serrated lock washer • B: Gearbox, axis 1 • C: Attachment screw, M12x80 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 285 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 286: Replacement Gearbox Axis 2
3HAC020999-001 Used to turn the gear in correct position. Standard toolkit Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 287 The procedure below details how to remove gearbox axis 2. Action Note Decide which calibration routine to use, and take actions accord- ingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 288 D : Hoisting block Drain the oil from gearbox axis 2. Detailed in the section Changing oil, axis-2 gearbox on page 154. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 289 Fit two guide pins in the holes, parallel to each other. CAUTION The gearbox weighs 98 kg! All lift- ing equipment used must be sized accordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 290 Note Make sure the o-ring is fitted to the gearbox. Lightly lubricate it with grease. xx0600003128 • A : O-ring 3HAB3772-91 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 291 The upper and lower arms (in- cl. gearboxes axes 2 and 3) weighs 455 kg. All lifting equipment used must be sized accordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 292 Axis Calibration is described in Calibrating with Axis Calibration method on page 319. General calibration information is included in section Calibration on page 305. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 293 These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 294: Replacement Of Gearbox Axis 3
Instructions 3HAC 026600-002 is enclosed. Lifting tool 3HAC025214-001 For lifting gearbox. Standard toolkit Content is defined in section Standard tools on page 346. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 295 The procedure below details how to remove gearbox axis 3. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 297 Calib- rating with Axis Calibration method on page 319. General calibration information is in- cluded in section Calibration on page 305. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 298 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 299: Replacement Of Gearbox, Axis 6
Attachment screws, gearbox Oil plug, draining Oil plug, filling Turning disk Attachment screws, turning disk xx0200000219 Gearbox, axis 6 (IRB 6620 Foundry Plus) Attachment screws and washers Oil plug, draining Oil plug, filling Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T ©...
Page 300 See refer- quired. ences to these pro- cedures in the step- by-step instructions below. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 301 214. Remove the gearbox by unscrewing its 8 attach- Shown in the figure Location of gearbox ment screws. on page 299. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 302 • hydraulic pressure supply to the ro- • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 303 Screw joints on page 342 before fitting. Refit the turning disc. Detailed in the section Refitting, turning disk on page 215. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 304 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 305: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 306: Calibration Methods
Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant. If no data is found related to standard calibration, Calibration Pendulum is used as default. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 307 Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 6620 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
Page 308 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 309: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 310: Synchronization Marks And Axis Movement Directions
The illustration below shows the positions of the synchronization marks on all axes of the robot. xx0600003096 Synchronization mark, axis 1 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 311 5.2.1 Synchronization marks and synchronization position for axes Continued Synchronization mark, axis 2 Synchronization mark, axis 3 Synchronization mark, axis 4 Synchronization mark, axis 5 Synchronization mark, axis 6 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 312: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 313: Updating Revolution Counters
This section describes how to do a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant. Revolution indicator The IRB 6620/IRB 6620 LX (not Foundry version) is equipped with a revolution indicator on axis 4. Location The revolution indicator is located as shown in figure.
Page 314 4 center. xx1500002404 If not: Jog the robot manually in the opposite direction to reach the correct position. xx1500002449 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 315 If one of the following mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 316 Step 2 - Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 317 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 318 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 334. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 319: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 320 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 321 To calibrate a suspended robot with the fine calibration routine, the robot must first be taken down and then be mounted standing on the floor. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 322: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 323 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 324: Installation Locations For The Calibration Tools
A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows. xx1600000001 xx1600000011 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 325 Replace damaged parts with new, if needed. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 326: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 327 Use this procedure to call for the Axis Calibration method on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 328 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 329 Confirm unsynchronized state by pressing Ac- knowledge to continue Axis Calibration proced- ure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 330 SafeMove generates the message "Unsynchron- ized time limit expired" (anytime). xx1500002482 Press OK to continue Axis Calibration procedure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 331 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC056806-001. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 332: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 333: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Remove any calibration equipment from the robot. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 334: Checking The Synchronization Position
If they do not, up- ization position for axes on page 310 date the revolution counters. Updating revolution counters on page 313. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 335: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 336 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 337: 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 338 This page is intentionally left blank...
Page 339: Reference Information
European standards Standard Description EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 340 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 341: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 342: 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 343 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 344 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 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 345: 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 346: Standard Tools
To be shortened to 12 mm Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 347: Special Tools
Description Art. no. Extension 300mm for bits 1/2" 3HAC12342-1 Guide pins M8 x 100 3HAC15520-1 Guide pins M8 x 150 3HAC15520-2 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 348 Lifting eye (used together with lifting tool 3HAC025333-005 3HAC 15556-1) Lifting tool, gearbox 3HAC025214-001 Guide pins, M12x130 3HAC022637-001 Guide pins, M16x Lifting eye, M16 3HAC14457-1 Lifting eye, M20 Crank Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 349: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
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Page 351: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 352 This page is intentionally left blank...
Page 353: Circuit Diagram
Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 354 9 Circuit diagram 9.1 Circuit diagrams Continued Product Article numbers for circuit diagrams Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001...
Page 355 Gravity Alpha, 92 calibration scales, 310 Gravity Beta, 91 CalibWare, 306 grease carbon dioxide extinguisher, 21 disposal, 335 cast iron guide pins, base plate, 82 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 356 FlexPendant, 316 motor axis 3, replacement, 253 updating, 313 motor axis 4, replacement, 260 risk of tipping, 65 motor axis 5, replacement, 265 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 357 347 restricting axis 1, 107 speed restricting axis 3, 109 adjusting, 114 stability, 65 standards, 339 zero position ANSI, 340 checking, 334 CAN, 340 Product manual - IRB 6620 3HAC027151-001 Revision: T © Copyright 2006-2018 ABB. All rights reserved.
Page 360 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 2006-2018 ABB. All rights reserved.

ABB IRB 6620 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Part Lists

9 Circuit Diagram

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