ABB IRB 6650S Product Manual
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ABB IRB 6650S Product Manual

ABB IRB 6650S Product Manual

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IRB 6650S

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Summary of Contents for ABB IRB 6650S

  • Page 1 ROBOTICS Product manual IRB 6650S...
  • Page 2 Trace back information: Workspace 22A version a16 Checked in 2022-03-11 Skribenta version 5.4.005...
  • Page 3 Product manual IRB 6650S - 200/3.0 IRB 6650S - 125/3.5 IRB 6650S - 90/3.9 M2000, M2000A, IRC5 Document ID: 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 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, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    2.5.1 Robot cabling and connection points ............Start of robot in cold environments ..............Test run after installation, maintenance, or repair ............ Maintenance Introduction ...................... Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 6 Replacing the turning disk ................ 4.4.2 Replacement of complete wrist unit ............4.4.3 Replacement of upper arm ................ 4.4.4 Replacement of complete lower arm ............Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 7 Type A vs type B motors ..................Spare part lists Spare part lists and illustrations ................Reference information Introduction ...................... Applicable standards ..................Unit conversion ....................Screw joints ....................Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 8 10.2 Circuit diagram 3HAC 025744-001 ................ 10.2.1 Validity of circuit diagram 3HAC025744-1 ............ 10.3 Circuit diagram 3HAC 13347-1 ................10.3.1 Validity of circuit diagram 3HAC13347-1 ............Index Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 9: Overview Of This Manual

    ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 6650S. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Document name Document ID Note Product specification - IRB 6650S Document.ID-1 Product specification - IRB 6600/6650/6650S 3HAC14064-1 M2000/M2000A Product manual, spare parts - IRB 6650S 3HAC049111-001 Circuit diagram 3HAC13347-1 3HAC025744-001 Product manual - IRC5 3HAC021313-001 IRC5 with main computer DSQC 639.
  • Page 11 198. Also a new circuit diagram is added to the manual, due to the new cabling. • IRB 6650S included in section Rebuilding parts in Product manual, spare parts - IRB 6650S. • New variant IRB 6650S - 90/3.9 is implemented throughout the manual.
  • Page 12 • Minor adjustments made in the text concerning counters in section Service Information System, M2000 on page 181. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 13 94. Also added signal about option 561-1 in section Inspect- ing the axis-1 mechanical stop pin on page 142. • Removed information about other robots than IRB 6650S from tables for oil type and amount in gearboxes, see Type of lubrication in gear- boxes on page 151.
  • Page 14 Published in release R17.1. The following updates are made in this revision: • Removed article number for press fixture (for pressing the pinion of the axis-5 motor). The fixture is not sold by ABB. Published in release R17.2. The following updates are made in this revision: •...
  • Page 15 Replacement of balan- cing device. • Text regarding fastener quality is updated, see Fastener quality on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 16 • Updated information about Gleitmo treated screws, see Screw joints on page 411. • Removed information about position switches as they are no longer available. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 17: Product Documentation, M2000/M2000A

    A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation.

  • Page 18: Product Documentation, Irc5

    Product documentation, IRC5 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 19 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 20: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 21: Safety

    The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.

  • Page 22: Requirements On Personnel

    The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 23: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 24 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 25: Safety Symbols On Manipulator Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 26 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 27 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 28 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 29 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 30 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 31: Robot Stopping Functions

    The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 • Product manual - IRC5 Panel Mounted Controller Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 32: Safety During Installation And Commissioning

    When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 33 Water • Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 34 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 35: Safety During Operation

    Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 36: Safety During Maintenance And Repair

    90 °C. Hot oil or grease Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 37 Hazards related to batteries Under rated conditions, the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 38 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 39: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 40: Brake Testing

    For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 41: Safety During Troubleshooting

    The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.

  • Page 42: Safety During Decommissioning

    Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 43: Installation And Commissioning

    Safety on page 21 before performing any installation work. Note Always connect the IRB 6650S and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: •...

  • Page 44: 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 45 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 46 This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 47 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP 67 Manipulator, protection type Foundry Plus IP 67 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 48: Working Range And Type Of Motion

    The following figures show the working ranges of the robot variants. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). IRB 6650S - 200/3.0 The illustration below shows the unrestricted working range of IRB 6650S - 200/3.0: xx0300000562 Continues on next page...
  • Page 49 2 Installation and commissioning 2.2.2 Working range and type of motion Continued IRB 6650S - 125/3.5 The illustration below shows the unrestricted working range of IRB 6650S - 125/3.5: xx0300000563 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG...
  • Page 50 2 Installation and commissioning 2.2.2 Working range and type of motion Continued IRB 6650S - 90/3.9 The illustration below shows the unrestricted working range of IRB 6650S - 90/3.9: xx0600002739 Marked area: max. payload 50 kg Continues on next page...
  • Page 51 Arm motion +160º to -40º Arm motion +70º to -180º Wrist motion +300° to -300° Bend motion +120° to -120° Turn motion +300° to -300° Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 52: Risk Of Tipping/Stability

    This figure shows the robot in its shipping position and transportation position. xx0300000632 WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 53: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 54: On-Site Installation

    Attachment points on robot The attachment points for the fork lift equipment are shown in this figure. Notice the length of the IRB 6650S balancing device when planning to lift with a fork lift, shown in the figure below. xx0300000463...
  • Page 55 Fork lift pocket (2 pcs, 3HAC15766-1 , 3HAC11264-1) Spacer (2 pcs) Horizontal attachment screws (4 pcs/ fork lift pocket) Vertical attachment screws (2 pcs) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 56 A Horizontal attachment screws, 4 pcs, M16 x 60. Tightening torque: 60 Nm. B Spacers, 2 pcs. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 57 M16, qual- ity 12.9)! Attachment points on robot are shown in figure Attachment points on robot on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 58 Reposition harness, if any, before using a fork lift! CAUTION The IRB 6650S robot weighs 2275 kg. All lifting accessories used must be sized ac- cordingly! Carefully lift the robot and move it to its install- ation site.

  • Page 59: Lifting Robot With Roundslings

    Position robot in a secure transport position. Attach roundslings to robot according to fig- Attachment points on page CAUTION The IRB 6650S robot weighs 2275 kg. All lifting accessories used must be sized accordingly! WARNING Personnel must not, under any circum-...
  • Page 60 The illustration is similar with the label attached to the robot’s lower arm. xx0400000679 Chain sling with shortener Roundsling, robot Roundsling, used to secure against rotation Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 61: Lifting Robot With Lifting Accessory

    The user manual may be out of date. The latest revision is available for download via myABB Business Portal, www.abb.com/myABB. xx0400000722 Required equipment Equipment Article number Note Lifting accessory, robot 3HAC15607-1 Includes user instructions 3HAC15971-2 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 62 Article number is specified in Required scribed in the enclosed instruction! equipment on page CAUTION The IRB 6650S robot weighs 2275 kg. All lifting accessories used must be sized ac- cordingly! WARNING Personnel must not, under any circumstances, be present under the suspended load! Raise overhead crane to lift the robot.

  • Page 63: Manually Releasing The Brakes

    The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 64 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 65: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 66: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 67 2 Installation and commissioning 2.3.6 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 68 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 69 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 70 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 71: Orienting And Securing The Robot

    M24 x 140 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 72 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 73 This illustration shows the hole configuration used when securing the robot. xx0300000046 Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0600002629 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 74: Fitting Equipment On Robot

    Make sure not to damage the robot cabling on the inside of the lower arm when fitting extra equipment. Always use appropriate attachment screws! xx0300000568 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 75 2 Installation and commissioning 2.3.8 Fitting equipment on robot Continued xx0300000569 xx0300000570 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 76 The illustration below shows the mounting holes available for fitting extra equipment on the upper arm. xx0300000574 xx0200000196 Only valid for IRB 6600 and IRB 6650 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 77 Illustration, fitting of extra equipment on frame The mounting holes available for fitting extra equipment on the frame are shown below. 6x M16 1180 xx0300000575 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 78 2.3.8 Fitting equipment on robot Continued Tool flange, standard The illustration below shows the mounting holes available for fitting equipment on the turning disc. xx0200000197 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 79 When fitting tools on the tool flange, only use screws with quality 12.9. For other equipment use suitable screws and tightening torque for your application. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 80: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 81: Installation Of Base Spacers (Option)

    Base plate 3HAC12937-8 Standard toolkit Content is defined in section Standard tools on page 415. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 82 M24 x 240, tightening torque: 775 Nm. closed attachment screws and washers. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 83: Installation Of Cooling Fan For Motors (Option)

    The fans are installed on the motors, axes 1 or 2, as shown in the figure below. xx1800000169 xx1800000170 Cooling fan, axis 1 Cooling fan, axis 2 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 84 • fan axes 1 & 2 cable harness • plate, customer • attachment screws and nuts. Cable harness inside control- 3HAC025488-001 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 85 Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 quality 8.8-A2F Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 86 Separate cabling for axis 1 or 2 The figure below shows the cabling used only for the fan on axis 1 or 2. xx0500002173 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 87 Run the cabling up through the base and frame, beneath the balancing device. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 88 Modifying options dialogue, by using the Modify Controller System Wizard in the Sys- tem Builder of RobotStudio. Read more about modifying the system in Operating manual - RobotStudio. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 89: Installation Of Foundry Plus Cable Guard (Option No. 908-1)

    Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found for registered users on myABB Business Portal (www.myportal.abb.com) and delivered with the Cable guard, article number 3HAC035933-001.

  • Page 90: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 91: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 92: Mechanically Restricting The Working Range Of Axis 1

    Includes attachment screws and an assembly drawing. Mechanical stop for axis 1, 15° 3HAC11076-2 Includes attachment screws and an assembly drawing. Standard toolkit Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 93 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 94: Extended Working Range, Axis 1 (Option)

    220 degrees. Related information The system parameters are described in detail in the reference manual, see References on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 95 How to define the range of movement in M2000/M2000A is detailed in User’s guide - S4Cplus (BaseWare OS 4.0), chapter System Parameters - topic Manipulator. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 96: Mechanically Restricting The Working Range Of Axis 2

    Art. no. is specified in section Refer- (BaseWare OS 4.0) (Robot- ences on page Ware 4.0) Technical reference manu- al - System parameters Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 97 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 98: Mechanically Restricting The Working Range Of Axis 3

    The figure shows IRB 7600 but the principle is the same. xx0300000048 Additional mechanical stops Fixed mechanical stop Attachment screw M16x60 quality 12.9 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 99 Art. no. is specified in section Refer- Ware OS 4.0) (RobotWare 4.0) ences on page Technical reference manu- al - System parameters Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 100 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 101: Electrical Connections

    See the Product manual - DressPack/SpotPack IRB 6650S/7600, see document number in References on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 102 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 103 Note How to ground DressPack/SpotPack cables is detailed in the Product manual - DressPack/SpotPack IRB 6650S/7600, see the document number in References on page Fan cables (option) These cables are not included in the standard delivery, but are included in the delivery if the fan option is ordered.
  • Page 104 Harness - cooling, 22 m 3HAC022723-005 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Harness - cooling, 30 m 3HAC022723-006 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 105: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 106: Test Run After Installation, Maintenance, Or Repair

    Verify the application in the operating mode manual reduced speed. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before initiating motion. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 107: Maintenance

    Note If the IRB 6650S is connected to power, always make sure that the IRB 6650S is connected to protective earth and a residual current device (RCD) before starting any maintenance work.

  • Page 108: 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 109: Maintenance Schedule

    • 12 months page 140 Inspection Dampers Every: Inspecting the damper on • 12 months axes 2-5 on page 147 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 110 165 24,000 hours • Changing oil, axis-6 Changing Oil in axis-6 gear- Every: gearbox on page 168 • 12,000 hours Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 111 Inspecting, signal lamp on page 149 12 months Inspection Mechanical stop Every: Inspecting the addi- axes 1-2-3 tional mechanical 12 months stops on page 144 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 112: 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 113: Inspection Activities

    Robots with protection type Foundry Plus have a transparent plug/sight glass installed in the evacuation holes. xx1800000101 xx1800000102 Protection filter (Standard). Transparent plug (Foundry Plus). Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 114 Replacing of motors is described in the repair chapter Motors on page 299. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 115: Inspecting The Oil Level In Axis-1 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 116 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 117: Inspecting The Oil Level In Axis-2 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 118 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 119: Inspecting The Oil Level In Axis-3 Gearbox

    Note! Do not mix with other oils! of oil in gearboxes on page 151. Standard toolkit Content is defined in section Standard tools on page 415. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 120 151. Further information about how to fill the oil may be found in the section Filling, oil on page 161. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 121 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 122: Inspecting The Oil Level In Axis-4 Gearbox

    Use this procedure to inspect the oil level in the axis-4 gearbox. Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 123 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technic- al reference manual - Lubrication in gear- boxes. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 124: Inspecting The Oil Level In Axis-5 Gearbox

    Handling gearbox oil involves several safety risks, Gearbox lubricants (oil or grease) on page Move the robot upper arm to a horizontal position. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 125 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 126: Inspecting The Oil Level In Axis-6 Gearbox

    To inspect oil level for wrist type 2, see Inspecting the oil level in axis-6 gearbox, wrist type 2 on page 128. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 127 Open the oil plug, filling and inspection. xx1300000244 Turn axis 6 so that the oil plug, draining faces up- wards. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 128 Use this procedure to inspect the oil level in the axis-6 gearbox, for wrist type 2. Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 129 Filling, oil, axis 6 on page 169. Refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 130 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 131: Inspecting The Balancing Device

    Piston rod (inside) Shaft, including securing screw Ear, bearing and o-rings Label with article number Inspect the surroundings Bearing, balancing device attachments Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 132 Required equipment on page 132. • balancing device (a ...replace the balancing device or consult ABB Robotics. tapping sound, How to replace the device is detailed in section Repla- caused by the springs cing the balancing device on page 288.
  • Page 133 Leaks at the o-rings and/or sealings, are not acceptable and must be attended to immediately in order to avoid any damage to the bearing! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 134 Clean the area at the front ear from old grease. Run the robot for some minutes, in order to move the balancing device piston. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 135 See the figure Inspection points, balancing device on page 131. Keep the areas around the balancing device clean and free from objects, such as service tools. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 136: Inspecting The Cable Harness

    Connectors at base Required equipment Equipment, etc. Art. no. Note Standard toolkit Content is defined in section Standard tools on page 415. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 137 Replace the cable harness if wear, cracks or Described in section Replacing cable damage is detected. harness, axes 1-6 on page 198. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 138 • 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 139 Replace the cable harness if wear, cracks or Described in section Replacement of damage is detected. cable harness, axes 5-6 on page 224! Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 140: Inspecting The Information Labels

    Warning label concerning shutting off power Information labels at gearboxes and at robot base, if gearboxes are filled with Kyodo Yushi TMO 150 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 141 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 405. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 142: Inspecting The Axis-1 Mechanical Stop Pin

    Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 143 The expected life of gearboxes can be reduced after collision with the mechanical stop. Make sure the mechanical stop pin can move in both directions. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 144: Inspecting The Additional Mechanical Stops

    The figure shows the location of the additional mechanical stops on axes 1, 2 and 3 (IRB 7600 shown). xx0200000150 Additional stop Fixed stop Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 145 Attachment screw and washer • Document for mechanical stop Standard toolkit Content is defined in section Standard tools on page 415. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 146 Required equipment on page 145. Correct attachment screws: • Axis 1: M16 x 35, quality 12.9. • Axis 2: M16 x 50 • Axis 3: M16 x 60 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 147: Inspecting The Damper On Axes 2-5

    Damper axis 3 3HAC12320-1 Damper axis 4 3HAC13564-1 Standard toolkit 3HAC15571-1 Content is defined in section Standard tools on page 415. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 148 If any damage is detected, the damper must be re- Art. no. is specified in Required placed with a new one! equipment on page 147. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 149: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 150 • 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 151: Replacement/Changing Activities

    The figure shows the location of the gearboxes. xx0800000247 Axis 1 gearbox Axis 2 gearbox Axis 3 gearbox Axis 4 gearbox Axis 5 gearbox Axis 6 gearbox Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 152 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 153: Changing Oil, Axis-1 Gearbox

    Oil collecting vessel Capacity: 8,000 ml. Oil exchange equip- 3HAC021745-001 Content is defined in section ment Special tools on page 416. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 154 Note Draining is time-consuming. Elapsed CAUTION time depends on the temperature of the oil. Drain as much oil as possible. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 155 Do not mix oil types! If wrong oil is refilled, the gear- box must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 156: Changing Oil, Axis-2 Gearbox

    Content is defined in section ment Special tools on page 416. Standard toolkit Content is defined in section Standard tools on page 415. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 157 • 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 158 Technical reference manual - Lubrication in gearboxes. Refit the oil plug and the plug in the vent hole. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 159: Changing Oil, Axis-3 Gearbox

    151. Oil exchange equipment 3HAC021745-001 Content is defined in section Special tools on page 416. Oil collecting vessel Capacity: 3,000 ml. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 160 Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. Refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 161 - Lubrication in gearboxes. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 162: Changing Oil, Axis-4 Gearbox

    Art. no. for the kit is specified in Required equipment on page 162. Action Note Run the upper arm -45° from the calibration position. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 163 Where to find type of oil and total page 122. amount is detailed in Type and amount of oil in gearboxes on page 151. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 164 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technic- al reference manual - Lubrication in gearboxes. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 165: Changing Oil, Axis-5 Gearbox

    Required equipment on page 165. Action Note Run axis 4 to a position where the oil plug for draining is facing downwards. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 166 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 151. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 167 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 168: Changing Oil, Axis-6 Gearbox

    Special tools on page 416. Oil collecting vessel Vessel capacity: 500 ml Standard toolkit Content is defined in section Standard tools on page 415. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 169 Gearbox lubricants (oil or grease) on page Remove the oil plug, filling. Shown in the figure Location of gearbox on page 168. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 170 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 126. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 171: Replacing The Smb Battery

    Battery pack with a 2-pole battery contact (DSQC) xx0300000559 SMB Battery cover SMB battery pack with 2-pole battery contact. Battery cable Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 172 Equipment, etc. Spare part no. Note Battery unit For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part approved equivalent. lists on page 405 Standard toolkit Content is defined in section...
  • Page 173 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 171. with a specified spare part or with an ABB- ap- proved equivalent. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG...
  • Page 174 Updating revolution coun- ters on IRC5 robots on page 374. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 175: Lubrication Activities

    Note! The balancing device must be mounted on the robot when lubricating the bearing! xx0400000721 Ear (spherical roller bearing located inside) Lubrication nipple Sealing spacer Hole through which the shaft is pressed Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 176 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 177 Inspection, balancing device - of the robot, in order to make sure there is Check for leakage on page 133. no incorrect leakage from the o-rings. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 178: Cleaning Activities

    General To secure high uptime it is important that the IRB 6650S 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 6650S.
  • Page 179 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
  • Page 180 Cooling fans Inspect the air supply inlet of the the motor cooling fans. Clean to remove any contamination that could hinder the air supply. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 181: Service Information System, M2000

    188. parameters are to be entered from an extern- al PC, a set of software tools are available to build such an application. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 182: Description Of Service Information System (Sis)

    Setting the SIS parameters on page 186. Remaining time Remaining time to next scheduled service date. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 183 Service interval exceeded When the service time has been exceeded for the selection made, an error message (Service interval exceeded!) is displayed. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 184 No data available When no data is available for the selection made, a message (No data available!) is displayed when trying to display the data. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 185: Sis System Parameters

    The values can be defined by the operating organization as knowledge of the robot's working conditions are accumulated. Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. Operation time limit (service level) The number of operation hours selected as service interval.

  • Page 186: Setting The Sis Parameters

    Select the required paramet- Available parameters are described in section SIS system ers by stepping up and parameters on page 185. down through the parameter list. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 187: Reading The Sis Output Logs

    How to set the value determining when the mes- gearbox x! sage is to be shown, is detailed in section Setting the SIS parameters on page 186. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 188: Exporting The Sis Data

    Operation time of gearbox axis 3 sisL10h_6 hours Gearbox time Estimated life of gearbox axis 6 sisL10h_Time_6 hours Gearbox time Operation time of gearbox axis 6 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 189: Repair

    Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 6650S, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 190: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 191: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 192 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 193: Mounting Instructions For Sealings

    If the sealing is without dust lip, just lubricate the main lip with a thin layer of grease. xx2000000071 A Main lip B Grease C Dust lip Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 194 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 195 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 196: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 197: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 198: Complete Robot

    R2.MP3 R2.FB2 R2.FB3 R2.MP1 R2.FB1 R1.MP R1.SMB xx2000001528 Rear cover plate Cable guide, inside the frame Cable gland, upper arm house Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 199 A linear guide is installed at the lower arm to make the cable harness run smoothly. When fitting cable harness 3HAC075000-001 to the robot, the linear guide 3HAC077402-001 must be installed. xx2100000302 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 200 DressPack cable harness Cable brackets of the upper arm xx0500002293 Cable bracket, wrist unit Cable bracket, upper arm tube Cable attachment, rear Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 201 B: Attachment screws, rear of cable bracket (2 pcs) • C: Attachment screw, bottom of cable bracket Pick out the cabling from motor, axis 6. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 202 In order to remove the cover completely, the connector R1.G must be disconnected! This causes a necessary updating of the revolution counter! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 203 Disconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 from the brake re- lease unit. xx0200000118 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 204 D Velcro strap Remove the cable gland securing the cables inside the lower arm. Remove the velcro strap and cable gland. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 205 Shown in the figure Location of cable harness on page 198. Make a note of the correct positions of the connectors! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 206 Shown in the figure Location of cable attachment screws. harness on page 198. Reconnect all connectors at motors axes 1 and Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 207 A Cable gland B Attachment screws, cable gland C Attachment plate D Velcro strap Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 208 Refit the cable gland securing the cables inside the lower arm. xx0100000142 Refit the velcro strap. (Bracket is not available on all robots.) xx2000001527 A Velcro strap Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 209 Fit a cable protection to the lower arm, if not already mounted, with two securing screws, M6x16. xx0500002320 Parts: • A: Securing screws, M6x16 (2 pcs) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 210 Refitting the harness, the lower end must first be refitted. cable harness - lower arm, frame and base on page 205. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 211 Note The position of axis 6 must be +90° for a cor- rect installation of the cable harness. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 212 Updating revolution the SMB unit has been broken, the revolution counters on IRC5 robots on page 374. counters now must be updated! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 213 4 Repair 4.3.1 Replacing cable harness, axes 1-6 Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 214: Replacement Of Cable Harness, Axes

    Replacing cable harness, axes 1-6 on page 198. (The divided cable for axes 1-4 is not applicable for robot model IRB 6650S - 90/3.9.) Location of cable harness The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below.
  • Page 215 Axis 2: 0 ° • Axis 3: 0 ° • Axis 4: 0 ° • Axis 5: +90 ° • Axis 6: no significance Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 216 Disconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 from the brake release unit. xx0200000118 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 217 • C: Attachment plate • D: Velcro strap Remove the cable gland securing the cables inside the lower arm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 218 Axis 2: 0 degrees • Axis 3: 0 degrees • Axis 4: 0 degrees • Axis 5: +90 degrees • Axis 6: no significance Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 219 Reconnect all connectors at motors 1 and 2. Specified and shown in the figure Location of cable harness on page 214! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 220 If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 221 Location of by refitting the velcro strap to the cable bracket cable harness on page 214! at the upper arm house. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 222 Refit the cable harness to the guide plate axis 2. Shown in the figure Location of cable harness on page 214. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 223 IRC5 robots on page 374. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 224: Replacement Of Cable Harness, Axes

    4.3.3 Replacement of cable harness, axes 5-6 General This cable is not applicable for robot model IRB 6650S - 90/3.9. Location of cable harness ax 5-6 The location of the cable harness, axes 5-6, is shown in the figure below.
  • Page 225 Continued Required equipment Equipment, etc. Spare part no. Note Cable harness axes 5-6 3HAC14140-1 Not applicable for IRB 6650S - 90/3.9. Standard toolkit Content is defined in section Standard tools on page 415. Other tools and procedures may These procedures include references be required.
  • Page 226 R3.FB5 and R3.MP5 and secure the harness ax 5-6 on page 224. cable bracket with the two attachment screws to the tube. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 227 M6. harness ax 5-6 on page 224. Be careful not to bend the attachment plate when fastening the screws! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 228 4.3.3 Replacement of cable harness, axes 5-6 Continued Action Note/Illustration Update the revolution counter! Detailed in section Updating revolution counters on IRC5 robots on page 374. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 229: Replacement Of Cabling, Axis 5 Motor

    Before entering the robot working area. Remove the complete wrist unit. Detailed in section: • Removal, wrist unit on page 243. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 230 General calibration information is in- cluded in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 231: Replacement Of Complete Arm System

    A more detailed view of the component and its position may be found in Spare part lists on page 405. xx0300000465 Upper arm Lower arm Frame Gearbox, axis 1 Base attachment screws Balancing device Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 232 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 233 Before entering the robot work- ing area. Drain the oil from gearbox axis Detailed in section Changing oil, axis-1 gearbox on page 153. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 234 The risk of damaging the interfaces is bigger if the load is lowered unbalanced! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 235 A Attachment holes for the guide pins, M12. B Guiding hole for the spring pin loc- ated in the gearbox, axis 1. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 236 General calibration information is included in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 237: Upper And Lower Arm

    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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 238 237. 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 239 See section • Changing oil, axis-6 gearbox on page 168 Refit any equipment removed during disas- sembly to the turning disk. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 240 4 Repair 4.4.1 Replacing the turning disk Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 241: Replacement Of Complete Wrist Unit

    Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5) Cable bracket Attachment point for lifting tool, wrist unit Wrist unit attachment screws and washers Upper arm tube Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 242 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 243 Fit the lifting accessory to the wrist unit. Art. no. is specified in Required equipment on page 242. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 244 241. (R3.FB5, R3.MP5) and secure the cable bracket with the two attachment screws to the tube. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 245 Shown in the figure Location of wrist unit on page 241. Tightening torque: 14 Nm±10%. Screw 3HAB3409-25 (with Loctite), Washer 3HAC062379-001. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 246 367. Refit any equipment previously removed from the turning disk. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 247: Replacement Of Upper Arm

    The lifting accessory is attached differently depending on whether the wrist unit is mounted on the upper arm or not. The attachment points are shown in the following figure. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 248 Continued A more detailed view of the component and its position may be found in Spare part lists on page 405. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 249 Motor, axis 3 Motor, axis 4 Attachment screws and washers, upper arm Sealing, axis 2/3 (between lower arm and gearbox axis 3) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 250 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 251 Fit the lifting accessory, upper arm to both attach- Note ments for lifting accessory. The different attachment points, depends on whether the wrist unit is mounted or not! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 252 Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Location of upper arm on page 247. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 253 The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting accessory to avoid injury to personnel! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 254 190. Refill the gearbox with oil. Detailed in section Changing oil, axis- 3 gearbox on page 159. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 255 General calibration information is in- cluded in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 256: Replacement Of Complete Lower Arm

    The figure (2) shows a cut through the lower arm pivot point in axis 2 (item B in the figure above!). Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 257 Gearbox Cover axis 2 O-ring Shaft, balancing device Grease Securing screw and washer, balancing device shaft Attachment screws and washers Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 258 Internal components for robots with protection Standard xx1100000955 Bearing Thrust washer Bushing Retaining ring, shaft Shaft, lower arm Protection washer Protection plug Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 259 For spare part num- Always use a new sealing when reas- ber see: sembling! • Spare part lists on page 405. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 260 For replacing the balancing device shaft. device shaft User instructions are enclosed with the tool. Lifting accessory, lower arm 3HAC14691-1 Tool that may be rented from ABB Robot- ics. Includes: • two guidings, 3HAC 14445-1, must be used for guiding the sealing, axis 2/3.
  • Page 261 Disconnect and remove the cables from inside Detailed in section Replacing cable the lower arm. harness, axes 1-6 on page 198. Release any cable attachments. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 262 Apply the lifting accessory to the lower arm. Art. no. is specified in Required equipment on page 259. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 263 Fit a new VK-cover on a new lower arm or re- Part no. is specified in Required place the existing if damaged. equipment on page 259. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 264 Art. no. is specified in Required equip- ment on page 259. Disconnect the power supply, if used. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 265 General calibration information is in- cluded in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 266: Replacement Of Lower Arm Shaft

    Components, lower arm shaft for robots with protection Standard The figure shows components fitted to the lower arm shaft when the robot has protection Standard. The figure shows IRB 6600, but is also valid for IRB 6650S! xx0300000487 Protection plug...
  • Page 267 Spare part lists on page 405. Puller device, axis 2 shaft 3HAC075427-001 Hydraulic pressing accessory. User instructions are enclosed with the tool. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 268 Foundry Prime) Removal, lower arm shaft from robot with protection Standard Use this procedure to remove the lower arm shaft if the robot has protection Standard. If encountering any problems when removing the shaft, contact ABB Robotics! Action Note/Illustration WARNING...
  • Page 269 Removal, lower arm shaft on robot with protection Foundry Plus Use this procedure to remove the lower arm shaft if the robot has protection Foundry Plus. If encountering any problems when removing the shaft, contact ABB Robotics! Action Note WARNING...
  • Page 270 Go to the user instructions enclosed with the press tool. DANGER Handling the tool incorrectly will cause serious in- jury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 271 Refit the thrust washer to the shaft. Also shown in the figure Compon- ents, lower arm shaft for robots with protection Foundry Plus on page 267! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 272 Refit the sealing cover onto the shaft. Press it tightly against the radial sealing while tightening the set screws. Use locking liquid. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 273 4.4.5 Replacement of lower arm shaft Continued Action Note/Illustration Proceed with the refitting procedure of the lower arm, detailed in section Replacement of complete lower arm on page 256. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 274: Securing The Lower Arm

    Holes for M16 bolts Required equipment Equipment, etc Art. no. Note Fixture lower arm 3HAC020729-001 Includes the locking screw for securing the lower arm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 275 Locking screw Adjusters, 2 pcs M16 bolts, 4 pcs Ring nuts, 2 pcs M12 bolts and washers, 2 pcs Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 276 The attachment holes of the mechanical stops are used to at- tach the fixture. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 277 2, according to section moval, gearbox axis 2 on page 348, provided that the balancing device is unloaded. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 278: Frame And Base

    Do not replace the battery contact! Equipment, etc. Article number Note SMB unit For spare part number, see: Spare part lists on page 405. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 279 Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards. xx1700000993 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 280 Update the revolution counters. Updating revolution counters on IRC5 robots on page 374. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 281: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 282 Location of the brake release unit is shown in the figure Location of brake release board on page 281. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 283 Refit the complete brake release board (includ- ing brake release board and bracket) to the SMB recess with the two attachment screws. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 284 Updating revolution counters on IRC5 robots on page 374. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 285: Replacement Of Spherical Roller Bearing, Balancing Device

    2 pcs required. O-ring 3HAB3772-76 2 pcs required. Sealing ring 3HAC11581-6 2 pcs required. Grease 3HAC042536-001 For lubrication of the com- ponents. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 286 • 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 287 Check for leak- could indicate damaged o-rings. age on page 133. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 288: Replacement Of Balancing Device

    Attachment screws, rear cover Balancing device shaft, including securing screw Bearing attachment Parallel pin (inside bearing attachment) Attachment screws, bearing attachments Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 289 Spare part no. Art. no. Note Balancing device Spare part Includes balancing device lists on page 405. 3HAC020040-001! Includes o-rings 3HAB3772- Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 290 3HAC11731-1 To be used with the press and puller tools. See technical specifications in the user instructions for the press equipment. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 291 289! to unload the weight. Attachments are shown in the figure Attachment points, balancing device on page 289. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 292 Remove the securing screw from the balancing Shown in the figure Location of balan- device shaft. cing device on page 288! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 293 Lubricate and refit the o-ring on the support Make sure the o-ring is seated prop- shaft. erly! Replace if damaged. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 294 Make sure not to burden the guide pins with the weight of the balancing device! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 295 Note pins. Make sure not to burden the guide pins with the weight of the balancing device! Remove the guide pins. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 296 Go to the user instructions enclosed with the press tool. DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 297 Go to the user instructions enclosed with the press tool. DANGER Handling the tool incorrectly will cause serious injury. Read and follow enclosed user instructions for the tool. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 298 Attachment hole for the secur- ing screw. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 299: Motors

    Includes on page 405. • motor • pinion • o-ring 21522012- 430. O-ring 21522012-430 Must be replaced when reassemling the motor. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 300 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 301 In order to release the brakes, connect the 24 VDC Connect to connector R2.MP1 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 302 Refit the cable gland cover at the cable exit with its Make sure the cover is tightly two attachment screws. sealed! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 303 General calibration information is included in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 304: Replacement Of Motor Axis 2

    M12x tools in pairs! Guide pins M10 x 150 3HAC15521-2 For guiding the motor. Guides are to be used in pairs! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 305 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 306 Make sure the gasket is not damaged! tachment screws. Disconnect all connectors beneath the motor cover. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 307 • 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 308 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 309 General calibration information is in- cluded in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 310: Replacement Of Motor, Axis 3

    3409-86 (M16 x 60). Grease 3HAC042536-001 For lubricating the o-ring. Removal tool, mo- 3HAC14631-1 Always use the removal tools tor M12x in pairs! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 311 See refer- ences to these pro- cedures in the step-by-step in- structions below. Circuit diagram See chapter Circuit diagram on page 421. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 312 Fit the mechanical stop to the third and final attach- ment hole (A), below the fixed stop (B) in the upper arm. See the figure above! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 313 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 314 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 315 Cal- ibrating with Axis Calibration meth- od on page 379. General calibration information is included in section Calibration on page 367. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 316 4 Repair 4.6.3 Replacement of motor, axis 3 Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 317: Replacement Of Motor, Axis 4

    Removal tool. motor M10x 3HAC14972-1 Always use the removal tools in pairs! Guide pins M8 x 100 3HAC15520-1 For guiding the motor. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 318 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 319 Remove the motor by gently lifting it straight Make sure the motor pinion is not dam- out. aged! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 320 Make sure the motor pinion does not get making sure the motor pinion is properly damaged! mated to the gear of gearbox 4. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 321 General calibration information is included in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 322: Replacement Of Motor, Axis 5

    21522012-430 Must be replaced when reassembling motor! Grease 3HAC042536-001 For lubricating the o-ring. Loctite 574, Flange sealant 12340011-116 Option Foundry Plus Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 323 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 324 Disconnect all connectors beneath the motor cover and remove the separate cable of the axis- 5 motor. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 325 Art. no. is specified in Required equip- the motor is seated properly. Lightly lubricate ment on page 322. the o-ring with grease. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 326 Performing a leak-down test on page 190. Refit the wrist unit. Detailed in the section Refitting, wrist unit on page 244. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 327 General calibration information is in- cluded in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 328: Replacement Of Motor, Axis 6

    • motor part lists on • pinion page 405. • o-ring 21522012-430 O-ring 21522012-430 Must be replaced when reas- sembling motor! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 329 Type A vs type B motors on page 403. Only fits type B motor. Type A vs type B motors on page 403. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 330 6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 331 Remove the guide pins. Secure the motor with its four attachment screws 4 pcs: M8 x 25, tightening torque: 24 and plain washers. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 332 • 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 333 6 and forwards in Removal, motor on page 330. Note Keep the old rear motor cover with the air nipple. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 334 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 331. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 335: Gearboxes

    Sealing ring 3HAC11581-4 Replace if damaged! Grease 3HAC042536-001 Shell Gadus S2 For lubricating the o-ring. Support, base and gear 1 3HAC15535-1 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 336 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 337 Detailed in section Removal, arm system on page 233. Unfasten the robot base from the foundation by removing the base attachment screws. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 338 Make sure the base remains in a stable position before performing any work under- neath the base! xx1000000364 A Support base (4 pcs) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 339 A view from below: • A: Oil drain hose • B: Attachment screws, gearbox axis 1, 18 pcs • C: Washers, 3 pcs Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 340 Turn the gearbox, and remove the protec- tion pipe by unscrewing two attachment screws. Note Move the protective pipe over to the new gearbox. xx1400000786 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 341 • A: Guide pin • C: O-ring 3HAB 3772-54 • D: O-ring 3HAB 3772-55 • E: Sealing ring 3HAC 11581-4 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 342 335. CAUTION The gearbox weighs 200 Kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 343 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs! lower it carefully to its mounting position. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 344 1, 18 pcs • C: Washers, 3 pcs Refit the cable guide in the center of gearbox 1 with its attachment screws. xx1000001393 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 345 General calibration information is in- cluded in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 346: Replacement Of Gearbox Axis 2

    Attachment holes inside of frame for the fixture, lower arm Attachment holes for the fixture, lower arm Motor, axis 2 Rear attachment screws, gearbox Cover, axis 2 Attachment screws, cover Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 347 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 348 Remove the rear attachment screws, gearbox from Shown in the figure Location of inside of the lower arm. gearbox on page 346! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 349 • 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 350 • A: Rear attachment screws, gearbox (18 pcs) • B: Holes for the guide pins, sealing axis 2/3 on the gearbox Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 351 Refit the cover, axis 2 to the frame with the Shown in the figure Location of gear- attachment screws, cover. box on page 346. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 352 General calibration information is in- cluded in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 353: Replacement Of Gearbox, Axis 3

    For spare part number, Includes Spare part lists on • gearbox page 405. • o-ring. Does not include the sealing, axis 2/3! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 354 These procedures include refer- may be required. See refer- ences to the tools required. ences to these procedures in the step-by-step instructions below. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 355 Secure the upper arm in a horizont- Art. no. is specified in Required equipment on al position using round slings. page 353. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 356 353. attachment screw holes. Fit the Lifting accessory RV2 ac- cording to figure. xx0900000113 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 357 Before entering the robot work- ing area. Turn the upper arm in such a position that the gear mating surface faces upwards. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 358 Replace if damaged! xx0200000173 • A: O-ring, gearbox axis 3 Lift the gearbox to its mounting position. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 359 General calibration information is included in section Calibration on page 367. DANGER Make sure all safety require- ments are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 360: Replacement Of Gearbox, Axis 6

    Spare part lists on page 405. Washers 3HAA1001-172 Not included in gearbox! Replace when damaged. O-ring 3HAB3772-58 Must be replaced when reas- sembling gearbox. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 361 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 362 238. Remove the gearbox by unscrewing its attach- Shown in the figure Location of gearbox ment screws. on page 360. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 363 • 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 364 Screw joints on page 411 before fitting. Refit the turning disc. Detailed in the section Refitting, turning disk on page 239. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 365 General calibration information is included in section Calibration on page 367. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 366 This page is intentionally left blank...

  • Page 367: 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 368: Calibration Methods

    To regain 100% Absolute accuracy perform- ance, the robot must be recalibrated for abso- lute accuracy after repair or maintenance that affects the mechanical structure. xx0400001197 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 369 Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 6650S. It is the recommended method in order to achieve proper performance. The following routines are available for the Axis Calibration method: •...
  • Page 370 Levelmeter calibration - alternative method Levelmeter calibration is referred to as the alternative method for calibration of ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.

  • Page 371: When To Calibrate

    The resolver values are changed If resolver values are changed, the robot must be re-calibrated 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 372: Synchronization Marks And Axis Movement Directions

    One of the marks is more narrow than the other and should be positioned within the limits of the wider mark. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 373: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 374: Updating Revolution Counters

    (try both directions, if needed). Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 375 CANCEL returns to the Calibration window. Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 376 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 377 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 378 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 395. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 379: 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 380 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 381 Make sure that the user rights admit to change the safety settings and to synchronize SafeMove. For robots with EPS, the same applies as for SafeMove. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 382: 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 383 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 384: Installation Locations For The Calibration Tools

    Replace damaged parts with new. 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 385: 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 386 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. The calibration method used at ABB factory for The FlexPendant will give all inform- each axis is shown, as well as calibration method ation needed to proceed with Axis used for the robot during last field calibration.
  • Page 387 Axis Calibration routine. When a warning message is displayed, tap Acknowledge to confirm the unsynchronized state and continue Axis Calibration procedure. CAUTION SafeMove must be synchronized after the calibration is completed. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 388 If the standard calibration data for axes 4, 5 or 6 Calibrating with Wrist Optimiz- should be updated with wrist optimization, run the ation method on page 392. calibration routine Wrist Optimization. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 389: Reference Calibration

    (step 5, see Brief introduction to Reference Calibration on page 389). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 390 10 Check again against the verification position. 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 391: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 392: Calibrating With Wrist Optimization Method

    3 Improved calibration data to the wrist axes is identified and presented. 4 Optimized positions for the wrist axes are presented. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 393 WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 394: 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. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 395: Checking The Synchronization Position

    If they do not, update the revolu- synchronization position for axes on tion counters. page 372 Updating revolution counters on page 374. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 396 If they do not, up- ization position for axes on page 372 date the revolution counters. Updating revolution counters on page 374. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 397: Decommissioning

    6 Decommissioning 6.1 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
  • Page 398 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 399: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 400: Decommissioning Of Balancing Device

    The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 401 • Inner spring: cut at least four coils! Double-check the number of coils cut and make sure all the tension in the springs is removed. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 402 This page is intentionally left blank...

  • Page 403: Robot Description

    The article numbers in the table can not be used for ordering spare parts. The numbers are only used for identification of installed motors. See Product manual, spare parts - IRB 6650S for spare part numbers. Robot axis Article number...
  • Page 404 Requirements/notes for replacing type A motor type A to type B with type B motor Fully interchangeable. Fully interchangeable. Fully interchangeable. Fully interchangeable. Fully interchangeable. Fully interchangeable. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 405: 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.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRB 6650S 3HAC020993-001 Revision: AG...
  • Page 406 This page is intentionally left blank...

  • Page 407: Reference Information

    9.1 Introduction 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 408: Applicable Standards

    ISO 13732-1:2006 Ergonomics of the thermal environment - Part 1 IEC 60974-1:2012 Arc welding equipment - Part 1: Welding power sources Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 409 Degrees of protection provided by enclosures (IP code) Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots. Only robots with protection Clean Room. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 410: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 411: Screw Joints

    9.4 Screw joints 9.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
  • Page 412 Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 413 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 414: 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 415: 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 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 416: Special Tools

    Gearbox crank, axis 2 3HAC020999-001 Guide pins M12 x 130 3HAC022637-001 Guide pins M12 x 150 3HAC13056-2 Guide pins M12 x 200 3HAC13056-3 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 417 3HAC021984-001 Tools that may be rented The following table specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual. The special tools are also listed directly in the instructions.
  • Page 418 3HAC055412- Delivered as a set of calibration tools. ibration Required if Axis Calibration is the valid calibration method for the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 419 Vacuum pump with regulator, hose and coupling • Couplings and adapters • Pump (manual) with hose and coupling • Graduated measuring glass • Oil gun • User instructions. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 420: Lifting Accessories And Lifting Instructions

    The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 421: Circuit Diagram

    Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 422 Circuit diagram - IRB 910SC 3HAC056159-002 Use the correct circuit diagram (IRB 6600, IRB 6650 and IRB 6650S) The cable harness of the robot is available in two different designs. Either the cabling is divided between the upper and lower arm, or not. Accordingly there are also two different versions of the circuit diagram.

  • Page 423: Circuit Diagram 3Hac 025744-001

    Label on the cable harness The label is located at the connectors in the base. Remove the rear cover plate to see the label. WebConfig Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 424: Circuit Diagram 3Hac 13347-1

    IRB 6650, IRB 6650S 3HAC 16331-1 IRB 7600 3HAC 14940-1 revision 0-2 For remaining cable harness assemblies, see section Validity of circuit diagram 3HAC025744-1 on page 423. Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.

  • Page 425: Index

    368 oil change axis 1, 153 verification, 394 gearbox axis 1, replacement, 335 when to calibrate, 371 gearbox axis 2, replacement, 346 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 426 47 dimensions, 74 protection type, 47 replacement, 256 protective equipment, 22 lower arm shaft, replacement, 266 protective wear, 22 lubricants, 36 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 427 375 safety devices, 33 troubleshooting safety equipment oil spills, 178 mechanical stop, 92 safety, 41 mechanical stop axis 2, 96 turning disk replacement, 237 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 428 3, 98 Wrist Optimization validity and responsibility, 21 overview of method, 392 velocity wrist unit, replacement, 241 adjusting, 105 verifying calibration, 394 zero position checking, 395 Product manual - IRB 6650S 3HAC020993-001 Revision: AG © Copyright 2004-2022 ABB. All rights reserved.
  • Page 430 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2004-2022 ABB. All rights reserved. Specifications subject to change without notice.

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