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IRB 6660
ABB IRB 6660 User Manual
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xx0400000715
Four
holes
for
alternative
clamping,
4x
Ø18
A
Continues
on
next
page
Product
manual
-
IRB
6660
77
3HAC028197-001
Revision:
S
©
Copyright
2007-2018
ABB.
All
rights
reserved.
2
Installation
and
commissioning
2.3.6
Securing
the
base
plate
Continued
76
78
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
9
Product Documentation
15
How to Read the Product Manual
17
1 Safety
19
General Safety Information
19
Limitation of Liability
19
Protective Stop and Emergency Stop
21
Safety Actions
22
Fire Extinguishing
22
Emergency Release of the Robot Axes
23
Make Sure that the Main Power Has Been Switched off
24
Safety Risks
25
Safety Risks During Installation and Service Work on Robots
25
Moving Robots Are Potentially Lethal
27
First Test Run May Cause Injury or Damage
28
Work Inside the Working Range of the Robot
29
Enabling Device and Hold-To-Run Functionality
30
Risks Associated with Live Electric Parts
31
The Unit Is Sensitive to ESD
33
Hot Parts May Cause Burns
34
Safety Risks Related to Pneumatic/Hydraulic Systems
35
Brake Testing
36
Safety Risks During Handling of Batteries
37
Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
38
Safety Signals and Symbols
40
Safety Signals in the Manual
40
Safety Symbols on Product Labels
42
2 Installation and Commissioning
49
Introduction
49
Unpacking
50
Pre-Installation Procedure
50
Working Range and Type of Motion
54
Risk of Tipping/Stability
58
On-Site Installation
60
Lifting Robot with Fork Lift
60
Lifting Robot with Roundslings
66
Lifting Robot with Lifting Slings
69
Manually Releasing the Brakes
73
Lifting the Base Plate
75
Securing the Base Plate
76
Orienting and Securing the Robot
81
Fitting Equipment on Robot
84
Installation of Chip Protection - IRB 6660
88
Installation of Cooling Fan for Motors (Option)
90
Installation of Foundry Plus Cable Guard (Option No. 908-1)
97
Loads Fitted to the Robot, Stopping Time and Braking Distances
98
Signal Lamp (Option)
99
Restricting the Working Range
100
Axes with Restricted Working Range
100
Mechanically Restricting the Working Range of Axis 1
101
Extended Working Range, Axis 1 (Option 561-1)
103
Electrical Connections
104
Robot Cabling and Connection Points
104
Start of Robot in Cold Environments
107
3 Maintenance
109
Introduction
109
Maintenance Schedule and Component Life
110
Specification of Maintenance Intervals
110
Maintenance Schedule
111
Expected Component Life
113
Inspection Activities
114
Inspecting the Oil Level in Axis-1 Gearbox
114
Inspecting, Oil Level Gearbox Axes 2 - 3
116
Inspecting the Oil Level in Axis-4 Gearbox
119
Inspecting the Oil Level in Axis-5 Gearbox
121
Inspecting the Oil Level in Axis-6 Gearbox
123
Inspecting, Balancing Device Bearings and Piston Rod Guide Ring
126
Inspection, Cable Harness
130
Inspecting the Information Labels
134
Inspecting the Axis-1 Mechanical Stop Pin
136
Inspecting the Additional Mechanical Stops
138
Inspecting the Damper on Axes 2-5
140
Inspecting, Signal Lamp (Option)
142
Replacement/Changing Activities
144
Type of Lubrication in Gearboxes
144
Changing Oil, Axis-1 Gearbox
146
Changing Oil, Gearbox Axes 2 and 3
149
Changing Oil, Axis-4 Gearbox
153
Changing Oil, Axis-5 Gearbox
156
Changing Oil, Axis-6 Gearbox
159
Replacing the SMB Battery
162
Lubrication Activities
166
Lubricating Balancing Device Bearings and Piston Rod
166
Cleaning Activities
169
Cleaning the IRB 6660
169
4 Repair
173
Introduction
173
General Procedures
174
Performing a Leak-Down Test
174
Mounting Instructions for Bearings
175
Mounting Instructions for Seals
177
Cut the Paint or Surface on the Robot before Replacing Parts
179
The Brake Release Buttons May be Jammed after Service Work
180
Complete Robot
181
Replacement of Cable Harness, Lower End (Axes 1-3)
181
Replacement of Process Cable Package 1 - 3 MH
189
Replacement of Cable Harness, Upper End
196
Replacement of Cabling, Axis 5 Motor
204
Replacement of Complete Arm System
207
Upper and Lower Arms
217
Replacing the Turning Disk
217
Replacement of Complete Wrist Unit
221
Replacement of Upper Arm
227
Replacing the Parallel Rod
238
Replacing the Complete Lower Arm
244
Replacement of Parallel Arm
252
Frame and Base
259
Replacing the SMB Unit
259
Replacing the Brake Release Board
262
Replacing the Balancing Device
266
Motors
274
Replacing Motor, Axis 1
274
Replacing Motors, Axes 2 and 3
281
Replacement of Motor, Axis 4
292
Replacement of Motor, Axis 5
297
Replacement of Motor, Axis 6
303
Gearboxes
311
Replacing the Axis 1 Gearbox
311
Replacing the Gearbox, Axes
324
Replacement of Gearbox, Axis
336
5 Calibration
341
Introduction to Calibration
341
Introduction and Calibration Terminology
341
Calibration Methods
342
When to Calibrate
344
Synchronization Marks and Axis Movement Directions
345
Synchronization Marks and Synchronization Position for Axes
345
Calibration Movement Directions for All Axes
347
Updating Revolution Counters
348
Calibrating with Axis Calibration Method
352
Description of Axis Calibration
352
Calibration Tools for Axis Calibration
354
Installation Locations for the Calibration Tools
356
Axis Calibration - Running the Calibration Procedure
357
Calibrating with Calibration Pendulum Method
363
Verifying the Calibration
364
Checking the Synchronization Position
365
6 Decommissioning
367
Introduction
367
Environmental Information
368
Scrapping of Robot
369
Decommissioning of Balancing Device
370
7 Reference Information
373
Introduction
373
Applicable Standards
374
Unit Conversion
376
Screw Joints
377
Weight Specifications
380
Standard Tools
381
Special Tools
382
Lifting Accessories and Lifting Instructions
385
8 Spare Part Lists
387
Spare Part Lists and Illustrations
387
9 Circuit Diagram
389
Circuit Diagrams
389
Other manuals for ABB IRB 6660
Product Manual, Spare Parts
40 pages
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ABB IRB 6660 Specifications
General
Brand
ABB
Model
IRB 6660
Category
Robotics
Language
English
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