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4.2 General procedures

4.2.1 Performing a leak-down test

When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.

Required equipment

Note

Article number

Equipment, etc.

-

Leak-down tester

-

Leak detection spray

Performing a leak-down test

Note

Action

Finish the refitting procedure of the motor or gear in
question.

1

Remove the upper oil plug on the gear and replace
it with the leak-down tester.

2

Regulators, which are included in the leak-down test,
may be required.

Correct value:

Use caution, apply compressed air and raise the
pressure with the knob until the correct value is
shown on the manometer.

CAUTION

The pressure must under no circumstance be higher
than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.

3

0.2-0.25 bar (20-25 kPa)

Disconnect the compressed air supply.

4

If the compressed air is signific-
antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.

Wait for approximately 8-10 minutes and make sure
that no pressure loss occurs.

5

If any pressure drop occurred, then localize the leak
as described in step

6

If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.

7

When the leak has been localized, take the necessary
measures to correct the leak.

8

212

Product manual - IRB 6650S

3HAC020993-001 Revision: Z

© Copyright 2004-2018 ABB. All rights reserved.

4 Repair

4.2.1 Performing a leak-down test

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Summary of Contents for IRB 6650S Series

Page 1: ...ROBOTICS Product manual IRB 6650S ...

Page 2: ...Trace back information Workspace R18 2 version a18 Checked in 2018 11 20 Skribenta version 5 3 012 ...

Page 3: ... manual IRB 6650S 200 3 0 IRB 6650S 125 3 5 IRB 6650S 90 3 9 M2000 M2000A IRC5 Document ID 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instructions ...

Page 5: ...1 Safety signals in the manual 44 1 4 2 Safety symbols on product labels 51 2 Installation and commissioning 51 2 1 Introduction 52 2 2 Unpacking 52 2 2 1 Pre installation procedure 56 2 2 2 Working range and type of motion 60 2 2 3 Risk of tipping stability 61 2 3 On site installation 61 2 3 1 Lifting robot with fork lift 66 2 3 2 Lifting robot with roundslings 68 2 3 3 Lifting robot with lifting...

Page 6: ...p 172 3 4 Replacement changing activities 172 3 4 1 Type of lubrication in gearboxes 174 3 4 2 Changing oil axis 1 gearbox 177 3 4 3 Changing oil axis 2 gearbox 180 3 4 4 Changing oil axis 3 gearbox 183 3 4 5 Changing oil axis 4 gearbox 186 3 4 6 Changing oil axis 5 gearbox 189 3 4 7 Changing oil axis 6 gearbox 192 3 4 8 Replacing the SMB battery 196 3 5 Lubrication activities 196 3 5 1 Lubricatio...

Page 7: ... 7 Gearboxes 356 4 7 1 Replacing the axis 1 gearbox 368 4 7 2 Replacement of gearbox axis 2 376 4 7 3 Replacement of gearbox axis 3 383 4 7 4 Replacement of gearbox axis 6 389 5 Calibration 389 5 1 Introduction to calibration 389 5 1 1 Introduction and calibration terminology 390 5 1 2 Calibration methods 393 5 1 3 When to calibrate 394 5 2 Synchronization marks and axis movement directions 394 5 ...

Page 8: ... tools 436 9 7 Special tools 440 9 8 Lifting accessories and lifting instructions 441 10 Circuit diagram 441 10 1 Circuit diagrams 443 10 2 Circuit diagram 3HAC 025744 001 443 10 2 1 Validity of circuit diagram 3HAC025744 1 444 10 3 Circuit diagram 3HAC 13347 1 444 10 3 1 Validity of circuit diagram 3HAC13347 1 445 Index 8 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB ...

Page 9: ...ersonnel working with an ABB Robot must be trained by 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 Organization of chapters The manual is orga...

Page 10: ...roduct specification IRB 6650S 3HAC14064 1 Product specification IRB 6600 6650 6650S M2000 M2000A 3HAC049111 001 Product manual spare parts IRB 6650S 3HAC13347 1 Circuit diagram 3HAC025744 001 3HAC021313 001 Product manual IRC5 IRC5 with main computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC021333 001 Product manual S4Cplus M2000 3HAC022419 001 Product manu...

Page 11: ...0 A complete undivided cabling from axis 1 to axis 6 is added to the spare parts in Spare part lists on page 425 New procedure Replacing cable harness axes 1 6 on page219 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 E New variant IRB 6650S 90 3 9 is implemented throughout the manual F...

Page 12: ...d or changes K Instruction for how to inspect oil level for wrist type 2 added see Inspect ing the oil level in axis 6 gearbox on page 145 Circuit diagrams are not included in this document but delivered as separate files See Circuit diagram on page 441 List of standards updated see Applicable standards on page 428 Interval changed for inspection and lubrication of balancing device Foundry Prime S...

Page 13: ...s on page 431 Added Safety risks during handling of batteries on page 39 The maximum allowed deviation in levelity of the base plate is changed see Securing the base plate on page 73 Corrected the article number for mechanical stops of axis 2 see Mech anically restricting the working range of axis 2 on page102 and Inspecting the additional mechanical stops on page 163 Reference to Hilti standard a...

Page 14: ...e done in this revision U Drawing of base plate is not available for purchase faulty information removed in Securing the base plate on page 73 Drawing of tool flange for LeanID added Added spare part number for protection cover and plug set Axis Calib ration Published in release R17 1 The following updates are made in this revision V Removed article number for press fixture for pressing the pinion...

Page 15: ... New periodic maintenance activity regarding inspection of the type B motor oil seal New gasket at axis 6 motor cable inlet Changed direction of installed cooling fan on axis 2 motor and removed a faulty image showing the design of the cooling fan Also added detailed images to installation procedure for the fan Published in release R18 2 The following updates are made in this revision Y New dimens...

Page 16: ...afety standards unit conversions screw joints lists of tools Spare parts list with exploded views or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Software manuals The software documentation consists of a wide range of manuals ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation A comp...

Page 17: ...ioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application ...

Page 18: ...he manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 18 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved Product documentation IRC5 Continued ...

Page 19: ...ompleted with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no is...

Page 20: ...This page is intentionally left blank ...

Page 21: ...rried out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is respon...

Page 22: ...orking in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure that...

Page 23: ...iew The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 6650S 23 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 24: ...uishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 24 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 25: ... may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury DANGER 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 manu...

Page 26: ...roller before proceeding work Note Switch off all main power switches in a MultiMove system Spot welding cabinet Wait for 5 minutes to let the capacitors discharge after the power has been switched off DANGER Even if the main switch is switched off the capacitors can cause electric shock if not given the time to discharge 26 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 AB...

Page 27: ...afety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the pur...

Page 28: ...odifications to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as...

Page 29: ... stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to ...

Page 30: ...fore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If ...

Page 31: ...in USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of the...

Page 32: ...anipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to pre...

Page 33: ...risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 7...

Page 34: ...e live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 34 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 35: ... Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of s...

Page 36: ...your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 36 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 3 8 Ho...

Page 37: ...re must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause a...

Page 38: ...as described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 38 Product manual IRB 6650S 3HAC020993 001 Revision Z Co...

Page 39: ...osion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures a...

Page 40: ...ion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic re...

Page 41: ... time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vol...

Page 42: ...e instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or deat...

Page 43: ... conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRB 6650S 43 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 44: ...lish German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of c...

Page 45: ...Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual IRB 6650S 45 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights re...

Page 46: ...p over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 46 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 47: ... 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual IRB 6650S 47 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 48: ...001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 48 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 49: ...hat this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual IRB 6650S 49 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Conti...

Page 50: ...This page is intentionally left blank ...

Page 51: ...portant that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page21 before performing any installation work Note If the IRB 6650S is connected to power always make sure that the robot is connected to protectiv...

Page 52: ...uired is suitable to handle the weight of the robot as specified in Weight robot on page 53 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 55 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 55 7 Before taking the robot to its installation ...

Page 53: ... robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz The table shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values ...

Page 54: ...obot mass including equipment i For information about compensating for founda tion flexibility see Application manual Control ler software IRC5 section Motion Process Mode i The minimum resonance frequency given should be interpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where t...

Page 55: ...the robot Value Parameter 5 Minimum ambient temperature 50 Maximum ambient temperature Max 95 at constant temperat ure Maximum ambient humidity Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP 67 Manipulator protection type Standard IP 67 Manipulator protection type Foundry Plus Product ...

Page 56: ...rm 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 56 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion ...

Page 57: ...tricted working range of IRB 6650S 125 3 5 xx0300000563 Continues on next page Product manual IRB 6650S 57 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 58: ...range of IRB 6650S 90 3 9 xx0600002739 Marked area max payload 50 kg A Continues on next page 58 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 59: ... Type of motion Note Range of movement Type of motion Axis 220º to 220º option 561 1 180 to 180 Rotation motion 1 160º to 40º Arm motion 2 70º to 180º Arm motion 3 300 to 300 Wrist motion 4 120 to 120 Bend motion 5 300 to 300 Turn motion 6 Product manual IRB 6650S 59 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type ...

Page 60: ...s the most stable position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position xx0300000632 WARNING The robot is likely to be mechanically unstable if not secured to the foundation 60 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All r...

Page 61: ...ent 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 Attachment points spacer and horizontal attachment screws A Attachment points horizontal attachment screws B Attachment points vertical attachment screws C Continues on next page Product manual IRB 6650S 61 3HAC020993 001 Revision Z Copyrigh...

Page 62: ...4 2 The Fork lift accessory 3HAC0604 2 is fitted to the robot as shown in the figure below xx0200000379 Fork lift pocket 2 pcs 3HAC15766 1 3HAC11264 1 A Spacer 2 pcs B Horizontal attachment screws 4 pcs fork lift pocket C Vertical attachment screws 2 pcs D Continues on next page 62 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and com...

Page 63: ...re 3 CAUTION The fork lift pocket weighs 60 kg 4 Always use original screws or replace ments of equivalent quality M16 qual ity 12 9 Secure the longer fork lift pocket to the spacers with four of the horizontal attachment screws and washers Note The screws which are attached horizontally and vertically are identical However they are tightened with different torque 5 Attachment points on the robot ...

Page 64: ...screws or replace ments of equivalent quality M16 qual ity 12 9 Attachment points on robot are shown in figure Attachment points on robot on page 61 CAUTION The fork lift pocket weighs 22 kg 8 4 pcs M16x60 Secure the shorter fork lift pocket on the other side of the robot with the four remaining hori zontal attachment screws 9 Tightening torque 60 Nm Always use original screws or replace ments of ...

Page 65: ...ifting accessories used must be sized ac cordingly 11 Carefully lift the robot and move it to its install ation site 12 WARNING Personnel must not under any circumstances be present under the suspended load 13 Refit the cooling fan to the motor if any 14 Product manual IRB 6650S 65 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting ...

Page 66: ...Action Position robot in a secure transport position 1 Attach roundslings to robot according to fig ure Attachment points on page 67 2 CAUTION The IRB 6650S robot weighs 2275 kg All lifting accessories used must be sized accordingly 3 WARNING Personnel must not under any circum stances be present under the suspended load 4 Continues on next page 66 Product manual IRB 6650S 3HAC020993 001 Revision ...

Page 67: ...el attached to the robot s lower arm xx0400000679 Chain sling with shortener A Roundsling robot B Roundsling used to secure against rotation C Product manual IRB 6650S 67 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting robot with roundslings Continued ...

Page 68: ...obot in any other position may result in the robot tipping over causing severe damage or injury Illustration lifting slings The figure below shows how to lift the complete robot with lifting slings xx0400000722 Required equipment Note Article number Equipment Includes user instructions 3HAC15971 2 3HAC15607 1 Lifting accessory robot Continues on next page 68 Product manual IRB 6650S 3HAC020993 001...

Page 69: ...ired equipment on page 68 Fit the lifting accessory to the robot as de scribed in the enclosed instruction 3 CAUTION The IRB 6650S robot weighs 2275 kg All lifting accessories used must be sized ac cordingly 4 WARNING Personnel must not under any circumstances be present under the suspended load 5 Make sure all hooks and attachments maintain their correct positions while lifting the robot Raise ov...

Page 70: ... brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 71 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpec ted ways Make sure no personnel is near or beneath the ro bo...

Page 71: ...e buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0600002937 Supply 0V on pin 12 and 24V on pin 11 2 Product manual IRB 6650S 71 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 Manually releasing the brakes Continued ...

Page 72: ...g All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 72 Fit lifting eyes in specified holes 2 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 3 72 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 A...

Page 73: ...x45º 0 3 Ø 45P7 A A Ø1 5 4x 6 3 4 8 2 1 6 3x45º B B 2 1 3 3x R1 3 x 4 3x 90º C C 4 5 K 7 0 5 0 47 0 25 c 2x R22 5 1 6 D 2 c 5 2 5 º Common Zone E F G H xx1000001053 Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page Product manual IRB 6650S 73 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installatio...

Page 74: ...or alternative clamping 4x Ø18 A Continues on next page 74 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Securing the base plate Continued ...

Page 75: ...or leveling bolts in the base plate A A A B B B B xx1500000312 Orienting grooves 3 pcs A Levelling bolts attachment holes 4 pcs B Continues on next page Product manual IRB 6650S 75 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Securing the base plate Continued ...

Page 76: ...Content is defined in section Standard tools on page 435 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Base plate This section details how to secure the base plate to the foundation Note Action Make sure the foundation is levelled 1 Continues on next pag...

Page 77: ...orienting grooves and leveling bolts on page 75 Fit the base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces o...

Page 78: ...the base plate B Levelling screws C Base plate attachment screws D Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation M24 x 140 Suitable screws lightly lubricated Quality 8 8 Quality Thickness 4 mm Suitable washer Outer diameter 44 mm Inner diameter 25 mm 725 Nm Tightening torque Continues on next page ...

Page 79: ...ase plate 3 Make sure the robot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 78 Fit the bolts and washers in the base attach ment holes 5 Shown in figure Illustration robot fitted to base plate on page 78 Note Lightly lubricate screws before as sembly Tighten bolts i...

Page 80: ...0300000046 Cross section guide sleeve hole This illustration shows the cross section of the guide sleeve holes xx0600002629 80 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Orienting and securing the robot Continued ...

Page 81: ...B 6650ID and IRB 6650ID is delivered with DressPack and there may not be any additional equipment fitted to the robot except at the turning disc and the frame Illustration fitting of extra equipment on lower arm The illustration below shows the mounting holes available for fitting extra equipment on the lower arm Make sure not to damage the robot cabling on the inside of the lower arm when fitting...

Page 82: ...69 xx0300000570 Continues on next page 82 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 83: ...ble 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 83 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 84: ...ra equipment on the frame are shown below 1180 800 240 50 40 541 471 6x M16 480 47 5 xx0300000575 Continues on next page 84 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 85: ...oles available for fitting equipment on the turning disc xx0200000197 Continues on next page Product manual IRB 6650S 85 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 86: ...max 99 I B B 1 6 0 3 A B 0 02 A xx1600000979 Fastener quality When fitting tools on the turning disk see the figures above only use screws with quality 12 9 Standard screws with quality 8 8 may be used when fitting other equipment to the mounting holes 86 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting eq...

Page 87: ...on delivered with the signal lamp Function 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 87 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 9 Signal lamp option ...

Page 88: ...no Equipment Includes mounting set with at tachment screws and mount ing instruction 3HAC021899 002 Base spacers 3HAC12937 8 Base plate Content is defined in section Standard tools on page 435 Standard toolkit Continues on next page 88 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 10 Installation of base spacers ...

Page 89: ...t position 2 Detailed in section Securing the base plate on page 73 Install the base plate to the foundation if not used previously 3 Shown in the figure Illustration install ation of base spacers on page 88 Fit the four base spacers and guiding sleeves to the base plate 4 Lift the robot with lifting slings and move it to the prepared base plate 5 Guide the robot with the guiding sleeves as loweri...

Page 90: ... for position switches and fans on page 115 separate cabling for axis 1 or 2 including only connections for the cooling fans on axes 1 or 2 Installation of this cabling is detailed in section Installation separate fan cabling axis 1 or 2 on page 94 Location of cooling fans The fans are installed on the motors axes 1 or 2 as shown in the figure below xx1800000170 xx1800000169 Cooling fan axis 1 A C...

Page 91: ...be fitted to the robot base if not already in stalled The plate is shown in the figure Plate for customer connections at base on page 92 3HAC025778 001 Plate for customer connec tions Additional cabling to and in side the controller The set includes fan axes 1 2 cable harness plate customer attachment screws and nuts 3HAC023999 001 Material set fan axes 1 and 2 3HAC025488 001 Cable harness inside ...

Page 92: ...quired Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Plate for customer connections at base xx0500002301 Plate for customer connections A Attachment screws 3 pcs M6x16 quality 8 8 A2F B Continues on next page 92 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and c...

Page 93: ...re shown in the figure Location of cooling fans on page 90 2 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox 3 Fit the parts of the fanbox to the motor and reassemble with the nine attachment screws 4 Lift the box axis 1 so that it does not rest directly on the robot and secure the box with the three tightening screws using locking liquid Tighten ...

Page 94: ...to the robot air pressure supply to the robot Before entering the robot working area 2 xx1800000161 Remove the rear cover plate from the robot base 3 Shown in the figure Separate cabling for axis 1 or 2 on page 93 Remove the cable bracket A 4 Art no is specified in Required equipment on page 91 xx1800000162 Fit the plate for customer connections if not already fitted to the connection plate of the...

Page 95: ...ame and base is not twisted and runs freely from the robot cabling 9 Refit the rear cover plate to the robot base 10 Install additional cabling to and inside the control ler 11 Also make adjustments in RobotWare as de scribed in the following procedure Adjustments in RobotWare Note Action RobotWare 4 0 modify the settings in RobIn stall RobotWare 4 063 and older must be up dated with a newer relea...

Page 96: ...0 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 96 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 12 Installation of Foundry Plu...

Page 97: ...oad diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software User s guide S4Cplus BaseWare OS 4 0 Operating manual IRC5 with FlexPendant 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 ...

Page 98: ...osition switch Axis 2 hardware mechanical stop and software signal from adjustable position switch Axis 3 hardware mechanical stop and software signal from adjustable position switch 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 t...

Page 99: ...he stop pin and one of the additional mechanical stops available for axis 1 xx0300000049 Additional mechanical stop A Stop pin B Required equipment Note Article number Equipment etc Includes attachment screws and an assembly drawing 3HAC11076 1 Mechanical stop for axis 1 7 5 Includes attachment screws and an assembly drawing 3HAC11076 2 Mechanical stop for axis 1 15 Standard toolkit Continues on n...

Page 100: ...is 1 on page 99 2 How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus BaseWare OS 4 0 chapter System Parameters topic Ma nipulator Adjust the software working range limitations system parameter configuration to corres pond to the mechanical limitations 3 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technica...

Page 101: ...Install position switches at axis 1 3 How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus BaseWare OS 4 0 chapter System Parameters topic Manip ulator Redefine the software working range limit ations in the system parameters topic Motion The Arm parameters Upper Joint Boundand Lower Joint Bound must be changed to 3 84 respectively 3 84 The values are in radians...

Page 102: ...ical stop B Required equipment Note Art no Equipment etc Includes six stops attachment screws washers and assembly drawings 3HAC13787 1 Mechanical stop set axis 2 Content is defined in section Standard tools on page 435 Standard toolkit Art no is specified in section Refer ences on page 10 User s guide S4Cplus BaseWare OS 4 0 Robot Ware 4 0 Technical reference manu al System parameters Continues o...

Page 103: ...de S4Cplus BaseWare OS 4 0 chapter System Parameters topic Manip ulator The software working range limitations must be redefined to correspond to the changes in the mechanical limitations of the working range 3 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters WARNING If the mechanical stop pin is deform...

Page 104: ...3 The illustration shows the mounting position of the mechanical stops on axis 3 The figure shows IRB 7600 but the principle is the same xx0300000048 Additional mechanical stops A Fixed mechanical stop B Attachment screw M16x60 quality 12 9 C Continues on next page 104 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 ...

Page 105: ...cal stop set axis 3 Content is defined in section Standard tools on page 435 Standard toolkit Art no is specified in section Refer ences on page 10 User s guide S4Cplus Base Ware OS 4 0 RobotWare 4 0 Technical reference manu al System parameters Continues on next page Product manual IRB 6650S 105 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning...

Page 106: ...aseWare OS 4 0 chapter System Parameters topic Manip ulator Note The software working range limitations system parameters must be redefined to correspond to the changes in the mechanic al limitations of the working range 3 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters WARNING If the mechanical stop p...

Page 107: ...itch axis 2 Includes only the position switch 3HAC16417 2 Position switch axis 3 Cabling to be installed on the robot 3HAC16659 1 Cabling position switches and cooling fans axes 1 2 and 3 See Illustration attachment plate for axis 2 switch on page 113 3HAC020113 001 Attachment plate for axis 2 switch An additional connection plate must be fitted to the robot base if not already installed The plate...

Page 108: ...directly to the connector in the base R1 SW1 xx0100000158 Position switch axis 1 A Cam B Set screw cam cam stop C Protection sheet D Rail E Rail attachment F Continues on next page 108 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Installation of position switches option Continued ...

Page 109: ... installed from the switch to the robot base xx0400001038 Position switch axis 2 A Cam B Rail C Rail attachment D Continues on next page Product manual IRB 6650S 109 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Installation of position switches option Continued ...

Page 110: ...ch axis 3 A Cam B Set screw cam cam stop C Rail E Rail attachment F Specifications Maximum voltage current for the position switches Value Parameter Max 50 VDC Voltage Max 1 A Current Continues on next page 110 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Installation of position switches option Continued ...

Page 111: ...that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Fitting and adjusting cams and stops The instruction below details how to fit and adjust the parts of the position switches Note Action Use a sharp knife and rubber hammer or similar Cut the cam to a suitable length 1 Shown in Illustration cutting the cam on page 112 Cut the e...

Page 112: ...rew A Adjustable cam B Profile C Illustration cutting the cam The illustration below show how to cut the position switch cam xx0100000114 Remove the gray section A Continues on next page 112 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Installation of position switches option Continued ...

Page 113: ...is 2 switch A xx1200000523 Continues on next page Product manual IRB 6650S 113 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Installation of position switches option Continued ...

Page 114: ...ustomer connections A Attachment screws 3 pcs M6x16 B Continues on next page 114 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Installation of position switches option Continued ...

Page 115: ...ss for position switches and fans The procedure below details how to fit the complete cable harness for position switches and cooling fans to the robot Note Action Move the robot to its calibration position 1 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the ro bot air pressure supply to the robot Before entering the robot working area 2 Continues on next page...

Page 116: ...ot cabling and through the side of the frame at mo tor axis 1 Secure the cabling going up to the axis 3 fan and position switch with existing velcro strap B attached around the robot cabling Connect the connector R2 SW2 to the position switch of axis 2 Note There is a risk of the balancing device damaging the fan cable if it is not protected by correct routing underneath the robot cabling 5 A Cabl...

Page 117: ...tch of axis 3 secure the cable going to the fan of axis 3 together with the robot cabling with a velcro strap 7 A Bracket lower arm Also shown in the figure Cable harness for posi tion switches and fans axes 1 3 on page 115 B Bracket for robot cabling C Connector R2 SW3 D Velcro strap Shown in the figure Cable harness for position switches and fans axes 1 3 on page 115 Secure the axis 3 fan cable ...

Page 118: ...wer arm is not twisted and is running free from the robot cabling 10 Refit the rear cover to the robot base 11 Cabling is specified in section Position switch cables robot base to controller option on page 121 Install additional cabling to and inside the control cabinet 12 118 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissi...

Page 119: ...ent fitted on the robot by the customer low voltage signals and high voltage power supply protective ground Customer cables option The customer cables also handle databus communication See the product manual for the controller see document number in References on page 10 Handles power supply to and control of the external axes motors as well as feedback from the servo system External axes cables o...

Page 120: ...e signal shielded 15 m 3HAC7998 3 Robot cable signal shielded 22 m 3HAC7998 4 Robot cable signal shielded 30 m Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Continues on next page 120 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 I...

Page 121: ...m the cables specified below are used for both position switches and cooling fans In a M2004 robot system however the cables below are only used for position switches Cabling for the cooling fans is specified in the table Fan cables option on page 122 Connection point cabinet Connection point robot Art no Cable XS8 R1 SW 3HAC13175 1 Position switch cable axis 1 7 m XS8 R1 SW 3HAC13175 2 Position s...

Page 122: ...he delivery if the fan option is ordered The cables are completely pre manufactured and ready to plug in Cabling to be installed on the robot is specified in section Installation of cooling fan for motors option on page 90 Cabling between robot base and control cabinet cooling fans M2004 The cables specified below are specific for the IRC5 controller and used when the robot is equipped with coolin...

Page 123: ...W2 3 3HAC022723 006 Harness cooling 30 m Inside cabinet A43 X10 and A43 X11 Product manual IRB 6650S 123 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Robot cabling and connection points Continued ...

Page 124: ...egulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 W...

Page 125: ...ections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 21 before performing any service work Note If th...

Page 126: ...will differ depending on how hard each part is run The SIS used in M2000 and M2000A is further described in the section Service Information System M2000 on page 202 The SIS used in M2004 is further described in the Operating manual Service Information System Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Connecte...

Page 127: ...pecting the oil level in axis 2 gearbox on page136 Every 12 months Oil level in axis 1 gearbox Inspection Inspecting the oil level in axis 2 gearbox on page136 Every 12 months Oil level in axis 2 gearbox Inspection Inspecting the oil level in axis 3 gearbox on page138 Every 12 months Oil level in axis 3 gearbox Inspection Inspecting the oil level in axis 4 gearbox on page141 Every 12 months Oil le...

Page 128: ...i reads 6 000 hours Oil in axis 2 gear box Kyodo Yushi TMO 150 Changing Second change when DTC iii reads 24 000 hours Following changes Every 24 000 hours Changing oil axis 3 gearbox on page180 Every 12 000 hours Oil in axis 3 gear box Optigear Synthetic RO Changing Do not mix with other oils Changing oil axis 3 gearbox on page180 First change when DTC iii reads 6 000 hours Oil in axis 3 gear box ...

Page 129: ... the robot iv The battery low alert 38213 Battery charge low is displayed when the battery needs to be replaced The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced See the replacement instruction for more details v The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot pow...

Page 130: ...ity Inspection position switch axes 1 2 and 3 on page 168 Every 12 months Position switches axes 1 2 3 Inspection 130 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 2 2 Maintenance schedule Continued ...

Page 131: ...e for the balancing device is based on a test cycle of 4 000 000 cycles that starts from the initial position and goes to maximum extension and back Deviations from this cycle will result in differences in expected life v Depending on application the lifetime can vary The Service Information System SIS that is integrated in the robot software can be used as guidance when planning gearbox service f...

Page 132: ... evacuation hole is located on each motor flange The figure shows axis 1 motor as an example xx1500001057 Plug in the evacuation hole Robots with protection type Standard have a protection filter installed in the evacuation hole Robots with protection type Foundry Plus have a transparent plug sight glass installed in the evacuation holes xx1800000102 xx1800000101 Transparent plug Foundry Plus Prot...

Page 133: ...isks during work with gearbox lubricants oil or grease on page 40 2 xx1500001057 Do a leakage check of the sight glass evacuation hole of each motor If any oil is available on the sight glass or if any oil has been spilled out from the evacuation hole replacement of the motor is recommended 3 Replacing of motors is described in the repair chapter Motors on page 320 Product manual IRB 6650S 133 3HA...

Page 134: ...ype and amount of oil in gearboxes on page 172 Lubricating oil Content is defined in section Standard tools on page 435 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 134 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright...

Page 135: ...ion of gear box on page 134 Open the oil plug inspection 4 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level max 10 mm below the oil plug hole 5 Where to find type of oil and total amount is detailed in Type of lub rication in gearboxes on page172 Adjust the oil level if required 6 Further information about how to fill with oil is found ...

Page 136: ...x with other oils See Type and amount of oil in gear boxes on page 172 Lubricating oil Content is defined in section Standard tools on page 435 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 136 Product manual IRB 6650S 3HAC020993 ...

Page 137: ...n the figure Location of gear box on page 136 Open the oil plug filling and inspection 4 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level max 5 mm below the inspec tion oil plug hole 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 172 Adjust the oil level if required 6 Filling of o...

Page 138: ...Oil plug draining C Required equipment Note Art no Equipment etc Note Do not mix with other oils See Type and amount of oil in gearboxes on page 172 Lubricating oil Content is defined in section Standard tools on page 435 Standard toolkit Continues on next page 138 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 4 Inspecting the oil ...

Page 139: ...the robot to a position according to the il lustration in Location of gearbox on page 138 2 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 3 This is a precaution to reduce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 4 Shown in the ...

Page 140: ...und in the section Filling oil on page 182 Tightening torque 24 Nm Refit the oil plug 8 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in Technical reference manual Lubrication in gearboxes 9 140 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 4 Inspecting the oil level in axis 3 gearbox ...

Page 141: ... to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level in axis 4 gearbox Use this procedure to inspect the oil level in the axis 4 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks...

Page 142: ...inspection 5 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level 0 10 mm 6 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 172 Adjust the oil level if required 7 Further information about how to fill the oil may be found in the section Filling oil on page 184 Tightening torque 24 Nm Ref...

Page 143: ...res include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level in axis 5 gearbox Use this procedure to inspect the oil level in the axis 5 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety inform ation in ...

Page 144: ...02222 Measure the oil level Required oil level to the upper edge of the filling and inspection oil plug hole a 30 mm 7 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 172 Adjust the oil level if required 8 Further information about how to fill the oil may be found in the section Filling oil axis 5 on page 187 Tightening torque 24 Nm Refit the o...

Page 145: ...ing and inspection B Oil plug draining C Inspection depending on type of wrist To inspect oil level for wrist type 1 see Inspecting the oil level in axis 6 gearbox wrist type 1 on page 146 To inspect oil level for wrist type 2 see Inspecting the oil level in axis 6 gearbox wrist type 2 on page 148 Continues on next page Product manual IRB 6650S 145 3HAC020993 001 Revision Z Copyright 2004 2018 ABB...

Page 146: ...ease read the safety informa tion in the section Safety risks during work with gearbox lubricants oil or grease on page 40 1 Move axes 3 and 5 to a horizontal position and make sure that the oil plug filling and inspection is facing upwards 2 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot work...

Page 147: ...or the oil plug filling and inspec tion Note If the oil plug draining is not opened then use a clean narrow object for example an oil stick or a cable tie to gently poke the oil surface This will avoid surface tension from stopping air to enter into the gearbox 9 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 172 Adjust the oil level if requir...

Page 148: ...reduce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 4 xx1300002447 Remove the oil plug filling and inspection 5 Slowly turn axis 4 until the axis 4 angle reads 72 5 to 77 5 6 A B C xx1400002786 A Oil plug hole B Required oil level C Gearbox oil Inspect the oil level in the hole for the oil plug filling and inspection The oil should reach all the way...

Page 149: ...in the section Filling oil axis 6 on page 190 Tightening torque 24 Nm Refit the oil plug 9 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in Technical reference manual Lubrication in gearboxes 10 Product manual IRB 6650S 149 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the oil level in axis 6 gear...

Page 150: ...d at the top rear of the frame as shown in the figure The figure also shows the inspection points further described in the instructions xx0400001025 Balancing device A Piston rod inside B Shaft including securing screw C Ear bearing and o rings D Label with article number E Inspect the surroundings F Bearing balancing device attachments G Continues on next page 150 Product manual IRB 6650S 3HAC020...

Page 151: ...he step by step in structions below Check for dissonance The check points are shown in the figure Inspection points balancing device on page 150 If dissonance is detected Check for dissonance from perform maintenance according to given instructions in Maintenance kit bearings and seals The replacement of the bearing at the ear is also detailed in section Re placement of spherical roller bearing ba...

Page 152: ...sible at the front of the balancing device 1 Art no for the kit and the documentation are specified in section Required equip ment on page 151 replace the securing screw in the front ear shaft Also check the tightening torque 50 Nm 2 Dimension is specified in section Required equipment on page 151 Check for leakage The front ear of the balancing device is lubricated with grease After filling exces...

Page 153: ...ssive grease from inside the front ear E Incorrect leakage from the front ear F Note Action Clean the area at the front ear from old grease 1 Run the robot for some minutes in order to move the balancing device piston 2 Continues on next page Product manual IRB 6650S 153 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the balancing device Contin...

Page 154: ...ing device on page 303 Incorrect leakage is shown in the previous figure Check for contamination lack of free space Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Check that there are no obstacles inside the frame that could prevent the balancing device from moving freely...

Page 155: ...e same for the harness that runs undivided from axis 1 to axis 6 xx0200000097 Lower arm A Cables attached with velcro straps and mounting plate B Connectors at cable harness division point R2 M5 6 C Connectors at base D Required equipment Note Art no Equipment etc Content is defined in section Standard tools on page 435 Standard toolkit Continues on next page Product manual IRB 6650S 155 3HAC02099...

Page 156: ...o detect wear and damage 2 Shown in the figure Location of cable harness axes 1 4 on page 155 Check the connectors at the division point and at the base 3 Location is shown in the figure Location of cable harness axes 1 4 on page155 Check that velcro straps and the mounting plate are properly attached to the frame Also check the cabling leading into the lower arm Make sure it is attached by the st...

Page 157: ...ness division point R2 M5 6 A Cable attachment rear of upper arm B Cable attachment upper arm tube C Inspection cable harness axes 5 6 The procedure below details how to inspect the cable harness of axes 5 6 Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Continues on...

Page 158: ...pper arm tube Check the connectors at the cable harness division Make sure the attachment plate is not bent or in any other way damaged 3 Described in section Replacement of cable harness axes 5 6 on page 241 Replace the cable harness if wear cracks or damage is detected 4 158 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspect...

Page 159: ...a flash located on motor cover 5 pcs B Instruction label C Warning label concerning brake release D Warning label tools are not allowed around the balancing device during operation I Warning label concerning shutting off power J 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 159 3HAC020993 001 Revis...

Page 160: ... off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare part lists on page 425 Replace any missing or damaged labels 3 160 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rig...

Page 161: ...option 561 1 Extended work range axis 1 is used Location of mechanical stop pin The axis 1 mechanical stop is located as shown in the figure xx0200000151 Mechanical stop pin A Required equipment Visual inspection no tools are required Continues on next page Product manual IRB 6650S 161 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the axis 1 ...

Page 162: ...area 1 Inspect the axis 1 mechanical stop pin 2 If the mechanical stop pin is bent or damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop Make sure the mechanical stop pin can move in both directions 3 162 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting...

Page 163: ...cation of the additional mechanical stops on axes 1 2 and 3 IRB 7600 shown xx0200000150 Additional stop A Fixed stop B Continues on next page Product manual IRB 6650S 163 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 12 Inspecting the additional mechanical stops ...

Page 164: ...tachment screw and washer Document for mechanical stop 3HAC13787 1 Mechanical stop axis 2 Includes Mechanical stop Attachment screw and washer Document for mechanical stop 3HAC13128 1 Mechanical stop set axis 3 Content is defined in section Standard tools on page 435 Standard toolkit Continues on next page 164 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights re...

Page 165: ...are damaged 2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 120 Nm Axes 2 and 3 115 Nm Article number is specified in Required equipment on page164 If any damage is detected the mechanical stops must be replaced Correct attachment screws Axis 1 M16 x 35 quality 12 9 Axis 2 M16 x 50 Axis 3 M16 x 60 4 Product manual IRB 6650S 165 3HAC020993 ...

Page 166: ...D Required equipment A damper must be replaced if damaged Note Spare part art no Equipment 3HAC12991 1 Damper axis 2 3HAC12320 1 Damper axis 3 3HAC13564 1 Damper axis 4 Content is defined in section Standard tools on page 435 3HAC15571 1 Standard toolkit Continues on next page 166 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 13 In...

Page 167: ...on page 166 Check all dampers for damage and for cracks or existing impressions larger than 1 mm To inspect the damper axis 4 remove the two covers on top of the upper arm 2 Check attachment screws for deformation 3 Art no is specified in Required equipment on page 166 If any damage is detected the damper must be re placed with a new one 4 Product manual IRB 6650S 167 3HAC020993 001 Revision Z Cop...

Page 168: ... to inspect the position switch axes 1 2 and 3 See the figures in section Installation of position switches option on page 107 to locate the different components to be inspected Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Check the position switch Check that the r...

Page 169: ... inside of the sheets is clean enough not to interfere the function of the position switch 5 Art no is specified in Required equipment on page 168 If any damage is detected the position switch must be replaced 6 Product manual IRB 6650S 169 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 14 Inspection position switch axes 1 2 and 3 Continued ...

Page 170: ...ver D Warning sign on motor cover E Required equipment Note Art no Equipment etc To be replaced in case of detected damage 3HAC10830 1 Signal lamp Content is defined in section Stand ard tools on page 435 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Con...

Page 171: ...obot Before entering the robot working area 2 Art no is specified in Required equipment on page 170 If the lamp is not lit trace the fault by Checking whether the signal lamp is broken If so replace it Checking cable connections Measuring the voltage in connectors motor axis 3 24V Checking the cabling Replace cabling if a fault is detected 3 Product manual IRB 6650S 171 3HAC020993 001 Revision Z C...

Page 172: ...l abb com Before starting any inspection maintenance or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in gearboxes A new revision wi...

Page 173: ...nser 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 173 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes Continued ...

Page 174: ...equipment Note Amount Art no Equipment etc Note Do not mix with other oils See Type and amount of oil in gear boxes on page 172 See Type and amount of oil in gearboxes on page 172 Lubricating oil Capacity 8 000 ml Oil collecting vessel Content is defined in section Special tools on page 436 3HAC021745 001 Oil exchange equip ment Continues on next page 174 Product manual IRB 6650S 3HAC020993 001 Re...

Page 175: ...sks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 40 2 Remove rear cover on the base by unscrewing its attachment screws 3 xx0200000237 Pull out the draining hose from the rear of the base 4 The hose is located beneath the base seen from below A Oil draining hose Vessel capacity is specified in Re quired e...

Page 176: ...everal safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 40 2 Shown in figure Location of oil plugs on page 174 Open the oil plug filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 172 Refill the gearbox with clean lubricating oil The co...

Page 177: ...ypes See Type and amount of oil in gearboxes on page 172 See Type and amount of oil in gearboxes on page 172 Lubricating oil Capacity 6 000 ml Oil collecting vessel Content is defined in section Special tools on page 436 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 435 Standard toolkit Continues on next page Product manual IRB 6650S 177 3HAC020993 001...

Page 178: ...lug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel CAUTION Drain as much oil as possible See Safety risks during work with gearbox lubricants oil or grease on page 40 4 Vessel capacity is specified in Required equipment on page 177 Note Draining is time consuming Elapsed time varies depending on the temperat ure of the oil Tightening torque 24 Nm Refit the...

Page 179: ...ailed in Type and amount of oil in gearboxes on page 172 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspect ing the oil level in axis 2 gearbox on page 136 4 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in Technical reference manual Lubrication in gearboxes 5 Tightening torque 24 Nm Refit the oil plug a...

Page 180: ...nt etc Note Do not mix with other oil types See Type and amount of oil in gear boxes on page 172 See Type and amount of oil in gearboxes on page 172 Lubricating oil Content is defined in section Special tools on page 436 3HAC021745 001 Oil exchange equipment Capacity 3 000 ml Oil collecting vessel Continues on next page 180 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB...

Page 181: ...ead the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 40 2 Remove the oil plug filling 3 Shown in the figure Location of gearbox on page 180 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel CAUTION Drain as much oil as possible See Safety risks during work with gearbox lubricants ...

Page 182: ...icants oil or grease on page 40 2 Shown in the figure Location of gearbox on page 180 Remove the oil plug filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 172 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspecting the oil level in axis 3 gearbox on page 138 4 WARNING Do not mix oil types I...

Page 183: ...ge 436 3HAC021745 001 Oil exchange equipment Capacity 9 000 ml Oil collecting vessel Content is defined in section Standard tools on page 435 Standard toolkit Draining oil The procedure below details how to drain the oil in the gearbox axis 4 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 183 Note Ac...

Page 184: ...the upper arm back to its calibration posi tion horizontal position 6 Tightening torque 24 Nm Refit the oil plug draining 7 Filling oil The procedure below details how to fill the oil in the gearbox axis 4 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 183 Note Action DANGER Turn off all electric pow...

Page 185: ... and total amount is detailed in Type and amount of oil in gearboxes on page 172 WARNING 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 4 Tightening torque 24 Nm Refit the oil plug filling 5 Product manual IRB 6650S 185 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 ...

Page 186: ...HAC021745 001 Oil exchange equipment Capacity 7 000 ml Oil collecting vessel Content is defined in sec tion Standard tools on page 435 Standard toolkit Draining oil axis 5 The procedure below details how to change the oil in gearbox axis 5 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 186 Note Actio...

Page 187: ...l axis 5 The procedure below details how to change the oil in gearbox axis 5 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit is specified in Required equipment on page 186 Note Action Run axis 4 to a position where the oil plug filling is facing upwards 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read ...

Page 188: ... and total amount is detailed in Type and amount of oil in gearboxes on page 172 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in Technical reference manual Lubrication in gearboxes 5 Tightening torque 24 Nm Refit the oil plug filling 6 188 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4...

Page 189: ... with other oils See Type and amount of oil in gearboxes on page 172 See Type and amount of oil in gearboxes on page 172 Lubricating oil Content is defined in section Special tools on page 436 3HAC021745 001 Oil exchange equip ment Vessel capacity Oil collecting vessel 500 ml Content is defined in section Standard tools on page 435 Standard toolkit Continues on next page Product manual IRB 6650S 1...

Page 190: ...lubricants oil or grease on page 40 3 Vessel capacity is specified in Re quired equipment on page 189 Drain the oil from the gearbox into a vessel by removing the oil plug 4 The amount of oil to be refilled de pends on the amount previously drained Measure the amount of oil drained Tightening torque 24 Nm Refit the oil plug draining 5 Filling oil axis 6 The procedure below details how to fill oil ...

Page 191: ...2 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspect ing the oil level in axis 6 gearbox on page 145 4 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in Technical reference manual Lubrication in gearboxes 5 Tightening torque 24 Nm Refit the oil plug 6 Detailed in the section Inspecting the oil level in ax...

Page 192: ...week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries Safety risks during handling of batteries on page39 Location of SMB battery The SMB battery SMB serial measurement board is located on the left hand...

Page 193: ...r the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not exchange battery contacts Note Spare part no Equipment etc Battery includes protection circuits Only re place with a specified spare part or an ABB approved equivalent For spare part no see Spare part lists on page 425 Battery unit Content is defined in section Standard tools ...

Page 194: ...er by unscrewing the attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Shown in figure Location of SMB battery on page 192 Pull out the battery and disconnect the battery cable 5 Shown in figure Location of SMB battery on page 192 Remove the SMB battery Battery includes protection circui...

Page 195: ...page 192 A B D C xx1300000307 A Battery pack RMU B Battery holder C Battery cable D Strap Strap the battery cable to the holder Shown in figure Location of SMB battery on page 192 Secure the SMB battery cover with its attachment screws 4 Detailed in chapter Calibration section Updating revolution coun ters on page 396 Update the revolution counters 5 DANGER Make sure all safety requirements are me...

Page 196: ...Note The balancing device must be mounted on the robot when lubricating the bearing xx0400000721 Ear spherical roller bearing located inside A Lubrication nipple B Sealing spacer C Hole through which the shaft is pressed D Continues on next page 196 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 5 1 Lubrication of spherical roller bea...

Page 197: ...ing device Check for leakage on page 152 Clean the area from any excessive grease and check the area once again after operation of the robot in order to make sure there is no incorrect leakage from the o rings 3 Lubrication balancing device bearing Design 2 The procedure below details how to lubricate the spherical roller bearing Note Action DANGER Turn off all electric power supply to the robot h...

Page 198: ...k for leakage on page 152 Clean the area from any excessive grease and check the area once again after operation of the robot in order to make sure there is no incorrect leakage from the o rings 3 198 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 5 1 Lubrication of spherical roller bearing balancing device Continued ...

Page 199: ... activities on page 132 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot Always check that all ...

Page 200: ... cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I 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...

Page 201: ...oling 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 201 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 6 1 Cleaning the IRB 6650S Continued ...

Page 202: ...in your production environment 2 Maintenance intervals recommended by ABB are specified in section Maintenance schedule and expected component life on page 126 How to do this is detailed in Setting the SIS parameters on page 207 Enter these parameters in the system 3 Run the robot in normal operation 4 The TPU displays for resetting any SIS value are shown in Description of Service Information Sys...

Page 203: ...n percentage of the axis 6 gearbox service interval Counters are reset when maintenance has been performed The counter status is displayed after running the service routine for maintenance Status OK indicates that no service interval limit has been exceeded by that counter Calendar time This is a clock within the control system that keeps track of the service interval based on calendar time When t...

Page 204: ...08 The following information is available about the joint service status in the service routine Service status for axis x i e the automatically calculated time parameter has not been exceeded Joint x OK The service interval for the axis in question has been reached Joint x NOK No service time parameter calculation available Joint x N A Applies to axes 4 and 5 IRB 6600 and IRB 7600 The following in...

Page 205: ...ction made a message No data available is displayed when trying to display the data Product manual IRB 6650S 205 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 7 2 Description of Service Information System SIS Continued ...

Page 206: ...rs selected as service interval E g by setting the value 2 the SIS will save this as the nominal time for activating the alarm not counting the percentage described below Calendar time warning A percentage of the Calendar time limit specified above E g by setting the value 90 the SIS will alert the operator after 90 of two years i e 657 days after a calendar time Reset was made the last time Gearb...

Page 207: ...m parameters using the TPU 1 Go to System paramet ers Manipulator types 2 2 Select 0 SIS parameters and press Enter 3 Select the required system The parameter list is dis played 4 Available parameters are described in section SIS system parameters on page 206 Select the required paramet ers by stepping up and down through the parameter list 5 Product manual IRB 6650S 207 3HAC020993 001 Revision Z ...

Page 208: ...it is detailed in section Setting the SIS parameters on page 207 Service Message Service is due X production hours since last service Operation time Proceed with the required service as detailed in chapter Repair on page211 or chapter Maintenance on page 125 depending on which type of service X number of operation hours remain until the manually set operation time limit expires Service Message X p...

Page 209: ...eration hours since the system was started Corresponds to the oper ating time counter on the control cabinet Operation time seconds sisTotRunT The number of operation hours since start last reset of the operation time counter Corres ponds to the operating time counter on the control cabinet Operation time seconds sisRunT Estimated life of gearbox axis 1 Gearbox time hours sisL10h_1 Operation time ...

Page 210: ...This page is intentionally left blank ...

Page 211: ...erform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 427 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure...

Page 212: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 213: ... any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the ...

Page 214: ...arted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description 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 214 Product manual IRB 6...

Page 215: ... correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page215 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreign...

Page 216: ...nly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically c...

Page 217: ...52 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual IRB 6650S 217 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights r...

Page 218: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 219: ...es 1 4 on page 232 Replacement of cable harness axes 5 6 on page 241 Location of cable harness The cable harness of axes 1 6 is run throughout the robot as shown in the figure below xx0500002176 Rear cover plate A Cable guide inside the frame B Cable gland upper arm house C Continues on next page Product manual IRB 6650S 219 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 R...

Page 220: ...agram Cable brackets of the upper arm xx0500002293 Cable bracket wrist unit A Cable bracket upper arm tube B Cable attachment rear C Removing the cable harness upper arm Use this procedure to remove the cable harness from the upper arm of the robot Note Action Axes 2 and 3 may be tilted slightly to improve access In order to facilitate refitting of the cable har ness run the robot to the specified...

Page 221: ...ly loc ated at the rear of the bracket and the third is located at the bottom of the cable bracket in the center 6 B Attachment screws rear of cable bracket 2 pcs C Attachment screw bottom of cable bracket Pick out the cabling from motor axis 6 7 Shown in the figure Cable brackets of the upper arm on page 220 Loosen the cable bracket upper arm tube by unscrewing the two screws on top of the tube 8...

Page 222: ...ocation of cable harness on page 219 Disconnect connectors R1 MP and R1 SMB 3 Pull the cable and connectors up through the cable guide in the center of the frame 4 Disconnect all connectors at motors 1 and 2 5 Open the SMB cover carefully 6 The cable between the battery and the SMB unit can stay connected in order to avoid an update of the revolution counter Be careful not to let the weight of the...

Page 223: ...ent plate When repla cing the cable harness make sure the correct one is used to avoid cable failure 8 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap Remove the cable gland securing the cables inside the lower arm 9 Remove the velcro strap and cable gland 10 Continues on next page Product manual IRB 6650S 223 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All ri...

Page 224: ...ow to refit on the upper arm is described in section Refitting the cable harness upper arm on page 229 Note Action Shown in the figure Location of cable harness on page 219 Push the cable and connectors down through the cable guide in the center of the frame Make sure the cables are not twisted with each other or with customer har nesses if any Make a note of the correct positions of the connector...

Page 225: ... Refit the rear cover plate to the robot with its attachment screws 4 Reconnect all connectors at motors axes 1 and 2 5 Continues on next page Product manual IRB 6650S 225 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness axes 1 6 Continued ...

Page 226: ...he velcro strap Shown in the figure Location of cable harness on page 219 Note Different robot versions are fitted with different versions of the attachment plate Make sure the correct one is used to avoid cable failure 6 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap Continues on next page 226 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ...

Page 227: ...he SMB cover and tighten with 6 Nm WARNING Before continuing any service work please observe the safety information in section The brake release buttons may be jammed after service work on page 218 9 Push the cable harness gently through the lower arm 10 xx0100000142 Refit the cable gland securing the cables inside the lower arm 11 Continues on next page Product manual IRB 6650S 227 3HAC020993 001...

Page 228: ...not already mounted with two securing screws M6x16 Secure the cable harness with two velcro straps with a distance of approximately 180 mm Fix the strap by wrapping it two turns around the largest cable before wrapping around the complete harness 13 Parts A Securing screws M6x16 2 pcs B Velcro straps 2 pcs Continues on next page 228 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004...

Page 229: ...n any direction 2 Reconnect all connectors on motors axes 3 and 4 3 Shown in the figure Location of cable harness on page 219 Secure the cable harness to the upper arm house by refitting the velcro strap to the cable bracket at the upper armhouse 4 Refit the velcro strap at the guide plate axis 2 Gently insert the cable harness from the rear into the upper arm 5 Shown in the figure Cable brackets ...

Page 230: ...ble bracket 1 pc Foundry robots Reconnect the connectors to motor axis 6 and refit the motor cover 10 It is recommended to use a new gasket on cover xx0200000214 Refit the cover upper arm tube and the cover wrist unit Make sure the cabling is placed correctly when refitting the covers and does not get jammed 11 Parts A Cover wrist unit Tightening torque 14 Nm Add Loctite to screw before fastening ...

Page 231: ...ng the first test run These are further detailed in the section First test run may cause injury or damage on page 30 15 Product manual IRB 6650S 231 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness axes 1 6 Continued ...

Page 232: ... 1 6 on page 219 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 xx0300000589 Rear cover plate A Attachment point for earth lug B Continues on next page 232 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB A...

Page 233: ...ontent is defined in section Standard tools on page435 Standard toolkit These procedures include references to the tools re quired Other tools and proced ures may be required See references to these proced ures in the step by step instructions below See chapter Circuit diagram on page 441 Circuit diagram Removal cable harness axes 1 4 The procedure below details how to remove the cable harness axe...

Page 234: ...enter of the frame 6 Specified and shown in the figure Location of cable harness on page 232 Disconnect all connectors at motors 1 and 2 7 Open the SMB cover carefully 8 The cable between the battery and the SMB unit may stay connected in order to avoid an update of the revolution counter Be careful not to let the weight of the cover strain the cable In order to remove the cover completely the con...

Page 235: ...ver sions of the attachment plate When replacing the cable harness make sure the correct one is used to avoid cable failure 10 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap Remove the cable gland securing the cables inside the lower arm 11 Continues on next page Product manual IRB 6650S 235 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Re...

Page 236: ...itting cable harness axes 1 4 The procedure below details how to refit the cable harness axes 1 4 Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Axes 2 and 3 may be tilted slightly to improve access In order to facilitate refitting of cable harness move the robot to ...

Page 237: ...ment point is shown in the figure Location of cable harness on page 232 Attachment point is shown in the figure Location of cable harness on page 232 Reconnect the earth cable 5 Shown in the figure Location of cable harness on page 232 Refit the rear cover plate to the robot with its at tachment screws 6 Specified and shown in the figure Location of cable harness on page 232 Reconnect all connecto...

Page 238: ...one is used to avoid cable failure 8 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap Reconnect connectors R2 SMB R1 SMB1 3 R1 SMB4 6 to the SMB unit 9 Reconnect X8 X9 and X10 to the brake release unit Reconnect R1 G if it has been disconnected Secure the SMB cover with its attachment screws 10 If cabling is used for 7th axis option refit the connector R2 FB7 to the ...

Page 239: ...on of cable harness on page 232 Reconnect all connectors at motor 3 and motor 4 15 Shown in the figure Location of cable harness on page 232 Reconnect the connector R2 M5 6 gently at the cable division point Be careful not to bend the attachment plate when fastening the screws 16 M6 2 pcs Shown in the figure Location of cable harness on page 232 Secure the cable harness to the upper arm house by r...

Page 240: ...cable harness to the guide plate axis 2 19 Shown in the figure Location of cable harness on page 232 Refit the velcro strap at the guide plate axis 2 20 Detailed in the Calibration chapter section Updating revolution coun ters on page 396 If the connection between the SMB battery and the SMB unit has been broken the revolution counters must now be updated 21 DANGER Make sure all safety requirement...

Page 241: ...cket wrist unit A Cable bracket upper arm tube B Connectors at motor axis 5 R4 FB5 and R4 MP5 C Connectors in upper arm tube R3 FB5 and R3 MP5 D Cable attachment rear F Connector at cable harness division point R2 M5 6 G Connectors at motor axis 6 R3 FB6 and R3 MP6 H Continues on next page Product manual IRB 6650S 241 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4...

Page 242: ...uded in this procedure The removal of that cable is described in section Removal cabling axis 5 motor on page 246 Note Illustration Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 xx0200000214 Remove the cover wrist unit and the cover upper arm tube 2 A cover wrist unit B ...

Page 243: ... rear 10 Shown in the figure Location of cable harness ax 5 6 on page 241 Disconnect connector R2 M5 6 at the cable harness division point 11 Gently pull the cable harness out 12 Refitting cable harness axes 5 6 The procedure below details how to refit the upper arm cable harness The separate cable that goes from the connection point inside of the upper arm tube to the motor axis 5 is not included...

Page 244: ...o motor axis 6 and refit the motor cover 6 xx0200000214 Refit the cover upper arm and the cover wrist unit Make sure the cabling is placed correctly when refitting the covers and does not get jammed 7 A Cover wrist unit Tightening torque 14 Nm Add Loctite to screw before fastening Screw 3HAB3409 25 Washer 3HAC062379 001 B cover upper arm tube If any cable straps have been removed refit them to the...

Page 245: ...ction Updating revolution counters on page 396 Update the revolution counter 11 Product manual IRB 6650S 245 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of cable harness axes 5 6 Continued ...

Page 246: ...ude references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Removal cabling axis 5 motor The procedure below details how to remove the cabling from the axis 5 motor Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Be...

Page 247: ... Refit the cable gland cover at the cable exit with its two attachment screws 3 Refit the cover of motor axis 5 4 Detailed in section Refitting wrist unit on page261 Refit the complete wrist unit 5 Calibration is detailed in a separate calibration manual enclosed with the calibration tools Re calibrate the robot 6 General calibration information is in cluded in section Calibration on page 389 DANG...

Page 248: ...re below A more detailed view of the component and its position may be found in Spare part lists on page 425 xx0300000465 Upper arm A Lower arm B Frame C Gearbox axis 1 D Base attachment screws E Balancing device F Continues on next page 248 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 5 Replacement of complete arm system ...

Page 249: ...ht be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence cali...

Page 250: ...e robot 3 Art no is specified in Required equipment on page249 Fit the lifting accessory and ad just it as detailed in the enclosed instructions 4 Make sure the lift is done completely level How to adjust the lift is described in the enclosed instruction to the lifting accessory Read the instructions before lifting DANGER Turn off all electric power supply to the robot hydraulic pressure supply to...

Page 251: ...ment screws M12x110 Art no is specified in section Required equipment on page 249 Fit two guide pins in two oppos ite screw holes 12 CAUTION The complete arm system weighs 1250 kg All lifting equipment used must be sized accordingly 13 Make sure all hooks and attachments stay in the cor rect position while lifting the arm system and that the lifting accessory does not wear against sharp edges Lift...

Page 252: ...g All lifting equipment used must be sized ac cordingly 3 Lift the complete arm system and move it at very low speed making sure it does not tip 4 Make sure the lift is done completely level Adjust the length of the chains as detailed in enclosed instruction or with a hoisting block Clean the mounting surfaces with isopropan ol 5 Dimension is specified in Required equipment on page 249 xx060000344...

Page 253: ...ricated as detailed in section Screw joints on page 431 before fitting Shown in the figure Location of arm sys tem on page 248 Refit the block for calibration at the bottom of the frame 11 Detailed in section Refitting motor axis 1 on page 323 Refit the axis 1 motor 12 Detailed in section Performing a leak down test on page 212 Perform a leak down test of the axis 1 gearbox 13 Refit the cabling in...

Page 254: ...eplaced when replacing the turning disk 3HAB3772 64 1 pc 3HAB3772 61 12 pcs O ring Wrist type 2 Used to lubricate the o rings 3HAB3537 1 Grease Loctite 574 3HAC034903 001 Flange sealant Content is defined in section Standard tools on page 435 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in ...

Page 255: ...rking area 2 Remove any equipment fitted to the turning disk 3 See section Changing oil axis 6 gear box on page 189 Drain the axis 6 gearbox 4 Shown in the figure Location of turning disk on page 254 Remove the attachment screws that secure the turning disk 5 Remove the turning disk 6 Foundry Plus 7 Remove old flange sealant residues and other con tamination from the contact surfaces Continues on ...

Page 256: ...Secure the turning disk with its attachment screws 3 Tightening torque 100 Nm Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page431 before fit ting Detailed in the section Performing a leak down test on page 212 Perform a leak down test of the gearbox axis 6 4 See section Changing oil axis 6 gearbox on page 189 Refill the axis 6 gearbox with oil 5 ...

Page 257: ...rming the first test run These are further detailed in the section First test run may cause injury or damage on page 30 7 Product manual IRB 6650S 257 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Continued ...

Page 258: ...xx0200000184 Wrist unit A Turning disk B Cover wrist unit C Cover upper arm tube D Connectors upper arm tube with cable bracket R3 FB5 R3 MP5 E Cable bracket F Attachment point for lifting tool wrist unit G Wrist unit attachment screws and washers H Upper arm tube I Continues on next page 258 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 ...

Page 259: ...s can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to ...

Page 260: ... page 258 Remove the cover upper arm tube 6 Remove the cover of motor axis 6 and discon nect all connectors beneath 7 Shown in the figure Location of wrist unit on page 258 xx0200000254 Loosen the cable bracket wrist unit on top of the wrist by undoing the three attachment screws Two of the attachment screws are visibly loc ated at the rear of the bracket and the third located at the bottom of the...

Page 261: ...ing area 1 Art no is specified in Required equip ment on page 259 Fit two guide pins M12 in the upper arm tube in two of the holes for the wrist unit attach ment screws 2 Shown in the figure Location of wrist unit on page 258 Art no is specified Location of wrist unit on page 258 Fit the lifting tool to the wrist unit 3 CAUTION The complete wrist unit weighs 130 kg All lifting equipment used must ...

Page 262: ... secure with with cable straps Cables are longer in order to fit different upper arm lengths 11 Parts A Cable straps Shown in the figure Location of wrist unit on page 258 xx0200000254 Fasten the cable bracket at top of the wrist unit with three attachment screws Two of them are visible at the rear attachment point and the third is located on the bottom of the cable bracket in the center 12 B Atta...

Page 263: ...ormation is in cluded in section Calibration on page 389 Refit any equipment previously removed from the turning disk 17 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 30 18 Product manual IRB 6650S 263 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserve...

Page 264: ...bes how to remove the upper arm when there is no wrist unit mounted Note 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 264 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of up...

Page 265: ...nt and its position may be found in Spare part lists on page 425 Continues on next page Product manual IRB 6650S 265 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of upper arm Continued ...

Page 266: ...g draining gearbox axis 3 C Cable harness division connector R2 M5 6 D Motor axis 3 E Motor axis 4 F Attachment screws and washers upper arm G Sealing axis 2 3 between lower arm and gearbox axis 3 H Continues on next page 266 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of upper arm Continued ...

Page 267: ...er with lifting eye M12 and lifting accessory upper arm 3HAC15556 1 Lifting tool chain Content is defined in section Standard tools on page 435 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Deciding calibration routine Decide which calibration routine t...

Page 268: ...ipment fitted to turning disk 2 Shown in the figure Location of upper arm on page 264 Move the upper arm to a horizontal position Rotate axis 4 so that the attachment hole for lifting eye is faced upwards 3 Rotate axis 5 to position 90 4 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working a...

Page 269: ...lifting equipment to take the weight of the upper arm 14 Connect to connector R2 MP3 pin 2 pin 5 In order to release the brake of the axis 3 motor connect the 24 VDC power supply Note When releasing the brake the position of the upper arm is adjusted to the position given by the lifting equipment 15 See Replacement of motor axis 3 on page 331 Remove the axis 3 motor 16 Shown in the figure Location...

Page 270: ...264 Art no is specified in Required equip ment on page 267 Upper arm including wrist unit Fit one of the pieces included in the lifting ac cessory upper arm to the front attachment for the lifting accessory on the upper arm 3 Attachment points are shown in the figure Location of upper arm on page 264 Note The different attachment points de pends on whether the wrist unit is mounted or not Upper ar...

Page 271: ...BRAKO tightening torque 120 Nm Secure the lower arm to gearbox axis 3 with the attachment screws 10 Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page431 before fit ting Remove the guide pins and fit the two remaining attachment screws Tighten them as detailed above 11 See Replacement of motor axis 3 on page 331 Refit the axis 3 motor 12 Remove the...

Page 272: ...d on page 401 General calibration information is in cluded in section Calibration on page 389 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 30 20 272 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 3 Replacemen...

Page 273: ...alancing device D Internal components lower arm The internal components of the lower arm are located as shown in the figure below The figure 1 shows a cut between the lower arm and the gearbox axis 3 The location of the sealing axis 2 3 is identical between the lower arm and the axis 2 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 274: ...alancing device J Grease K Securing screw and washer balancing device shaft L Attachment screws and washers N Continues on next page 274 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 4 Replacement of complete lower arm Continued ...

Page 275: ...earing D Thrust washer E Bushing F Retaining ring shaft G Shaft lower arm H Protection washer I Protection plug M Continues on next page Product manual IRB 6650S 275 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 4 Replacement of complete lower arm Continued ...

Page 276: ...adial sealing with dust lip M Required equipment Note Art no Equipment etc Always use a new bearing when reas sembling For spare part num ber see Spare part lists on page 425 Bearing Always use a new sealing when reas sembling For spare part num ber see Spare part lists on page 425 Sealing axis 2 Continues on next page 276 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB ...

Page 277: ...c pump 80 MPa 3HAC021563 012 Hydraulic pump 150 MPa Glycerin The use of the tool is detailed in section Replacement of lower arm shaft on page 283 3HAC021563 001 Puller device axis 2 shaft 3HAC021600 001 Press device axis 2 shaft 3HAC13527 1 Press tool axis 2 bearing Retaining ring plier For lubrication of the shaft hole 3HAB3537 1 Grease For cleaning of the shaft 11771012 208 Isopropanol Content ...

Page 278: ...Reference calibration routine on page 402 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Remo...

Page 279: ...n the frame The shaft has a M20 thread diameter as shown in the figure to the right Pull the shaft out using the puller tool and the hydraulic pump 8 Note The dimension of the shaft puller tool is M20 Do not mix up with the shaft press tool used when mounting the shaft Lower the balancing device until it rests safely against the bottom of the frame 9 xx0400001028 Move the lower arm backwards to th...

Page 280: ...no is specified in Required equipment on page 276 Fit a new VK cover on a new lower arm or re place the existing if damaged 2 Art no is specified in Required equip ment on page 276 xx0300000548 Fit two guidings in the attachment holes of the lower arm 3 A Attachment holes for the two guid ings Always use a new sealing when reas sembling Fit the new sealing axis 2 3 on the guidings 4 Art no is spec...

Page 281: ...g Shown in the figure Internal compon ents lower arm on page 273 Remove the guidings and secure the two re maining screws as detailed above 11 Refit the lower arm shaft and all additional components as detailed in section Replace ment of lower arm shaft on page 283 12 Remove the lifting tool from the lower arm 13 See section Replacing the balancing device on page 306 Refit and restore the balancin...

Page 282: ...page 401 General calibration information is in cluded in section Calibration on page 389 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 30 20 282 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 4 Replacement of ...

Page 283: ...lancing device and removing the front eye shaft draining the oil in gearbox axis 2 unloading the lower arm with specific lifting equipment 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 A Lower arm sh...

Page 284: ...8 4x16x1 6 G Shaft tap H Shaft for the sealing cover J O ring K Sealing cover L Radial sealing with dust lip M Required equipment Note Article number Equipment Always use a new bearing when reassembling For spare part number see Spare part lists on page 425 Bearing 3HAC021563 001 Puller device axis 2 shaft 3HAC021600 001 Press device axis 2 shaft Continues on next page 284 Product manual IRB 6650S...

Page 285: ... 3106 3HAC026621 001 Rust preventive Loctite 243 3HAB7116 1 Locking liquid only for robots with protection Foundry Plus and Foundry Prime Puller device for removal of axis 2 shaft The illustration below shows the puller tool used to remove the lower arm shaft axis 2 shaft xx0400001029 Nipple for the hydraulic pump A Nipple for the glycerin pump B Continues on next page Product manual IRB 6650S 285...

Page 286: ...ms when removing the shaft contact ABB Robotics Note Illustration Action WARNING This procedure is a step in the complete procedure of removing the lower arm Make sure all the preceding steps specified in Re placement of lower arm shaft on page283 are made before removing the lower arm shaft 1 Shown in the figure Components lower arm shaft for robots with protection Standard on page 283 Remove the...

Page 287: ...s on the tool are shown in figure Puller device for removal of axis 2 shaft on page 285 Note Do not exceed the limit of maxim um pressure classified for the pumps Increase the pressure of the glycerin pump and at the same time pull out the shaft with the puller tool by increasing the pressure of the hydraulic pump 6 Remove the bearing and thrust washer from the shaft hole in the lower arm recommen...

Page 288: ...s lower arm shaft for robots with protection Foundry Plus on page 284 Remove the two set screws 2 Remove the shaft sealing cover 3 Remove the sealing cover 4 Remove the radial sealing if the lower arm is to be replaced with a new one 5 If the same lower arm is refitted the radial sealing can be left in the lower arm Remove the hexagon bolt with the washer and shaft tap 6 Art no is specified in Req...

Page 289: ...re Compon ents lower arm shaft for robots with protection Standard on page 283 Refit the thrust washer to the shaft 3 Art no is specified in Required equipment on page 284 Apply the press device axis 2 shaft against the shaft 4 Tightening torque 20 Nm Tighten the M16 nut 5 Art no is specified in Required equipment on page 284 Fit both the hydraulic pump and the glycerin pump to the press device 6 ...

Page 290: ...ropanol and lubricate it with glycerin 1 Push the shaft in by hand 2 Also shown in the figure Compon ents lower arm shaft for robots with protection Foundry Plus on page 284 Refit the thrust washer to the shaft 3 Art no is specified in Required equipment on page 284 Apply the press device axis 2 shaft against the shaft 4 Tightening torque 20 Nm Tighten the M16 nut 5 Art no is specified in Required...

Page 291: ...th protection Foundry Plus on page 284 Fit a radial sealing to the lower arm if there is none left during removal of the arm 14 Refit the hexagon bolt with a spring washer and a shaft tap through the hole in the lower arm shaft 15 Fit the shaft for the sealing cover onto the hexagon bolt and tighten the bolt with torque 24 Nm 16 Check the o ring in the sealing cover Replace if damaged 17 Refit the...

Page 292: ...m is fitted to the attachment points shown in the figure below xx0300000608 Attachment hole securing screw A Holes for M12 bolts B Holes for M16 bolts C Required equipment Note Art no Equipment etc Includes the locking screw for securing the lower arm 3HAC020729 001 Fixture lower arm Continues on next page 292 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights re...

Page 293: ...nd ring nuts are attached to the fixture tool as shown in the figure below Move them to the attachment points shown in the instruction xx0300000609 Locking screw A Adjusters 2 pcs B M16 bolts 4 pcs C Ring nuts 2 pcs D M12 bolts and washers 2 pcs E Continues on next page Product manual IRB 6650S 293 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 6 Securing the lo...

Page 294: ...0 Move the robot to the calibration position The upper arm can be directed in three different ways shown in the figure to the right The lowered position as in figure A is recommended as it gives the least load on the tool 3 If the robot is fitted with moveable mechanical stops on axis 2 not stock equipment these must be removed at this point 4 The attachment holes of the mechanical stops are used ...

Page 295: ...on the inside of the frame with tightening torque 220 Nm A 5 Screw in the two adjusters until they rest against the flats on the lower arm Tighten by hand 6 Lock using the two ring nuts 7 Fit and tighten the two M12 bolts in the attachment holes on the lower arm with tightening torque 91 Nm C 7 Attachment holes on the frame and on the lower arm are shown in the figure Attachment points robot on pa...

Page 296: ...units and batteries The variant with the 3 pole battery contact has longer lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Note Article number Equipment etc For spare part number see Spare part lists on page 425 SMB unit Continues on next page 296 Product manual IRB 6650S 3HAC020993 00...

Page 297: ...y unscrewing its attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Use caution and remove the connectors X8 X9 and X10 from the brake release board if need of more space 5 Shown in the figure Location of SMB unit on page 296 Remove the nuts and washers from the guide pins that secure the...

Page 298: ...296 Fit the SMB unit onto the guide pins 5 Secure the SMB unit to the pins with the nuts and washers 6 X9 X8 X10 xx1700000978 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 7 Shown in the figure Location of SMB unit on page 296 Secure the SMB cover ...

Page 299: ...ed equipment Note Article number Equipment etc DSQC1050 3HAC065020 001 Brake release board Content is defined in section Standard tools on page 435 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 6650S 299 3HAC0209...

Page 300: ...MB cover by unscrewing the attach ment screws Let the battery stay connected to avoid the need of synchronization of the robot CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board 5 Remove the complete br...

Page 301: ... 2 Maximum tightening torque 5 Nm Fasten the brake release board on the bracket with the attachment screws 3 Shown in the figure Location of brake release board on page 299 Make sure the board is pushed forwards and positioned as straight as possible on the bracket when fastening with the attachment screws The push buttons can otherwise get jammed when the SMB cover is refitted xx1700001153 Art no...

Page 302: ...8 7 Shown in the figure Location of brake release board on page 299 Refit the push button guard to the SMB cover 8 Press the push buttons 1 to 6 one at a time to make sure that the buttons are moving freely and do not stay in a locked position 9 Detailed in the Calibration chapter section Updating revolution counters on page 396 If the battery has been disconnected the revolu tion counter must be ...

Page 303: ...alancing device E Required equipment Note Art no Spare part no Equipment 3HAA2167 17 Spherical roller bear ing 2 pcs required 3HAC12988 1 Sealing spacer 2 pcs required 3HAB3772 76 O ring 2 pcs required 3HAC11581 6 Sealing ring For lubrication of the com ponents 3HAB3537 1 Grease Continues on next page Product manual IRB 6650S 303 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserve...

Page 304: ...s tool for removal of bearing C Press tool for refitting of bearing D Hexagon nut M12 2pcs E Plain washer 13x24x2 5 2pcs F Removal spherical roller bearing Use this procedure to remove the spherical roller bearing from the balancing device front ear Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before ente...

Page 305: ...in the bearing properly inside the ear 3 Spare part no s are specified in Required equipment on page 303 Apply grease to the new sealing rings and o rings and fit one of each to the new seal ing spacers Also grease the sealing spacers 4 Detailed in section Refitting balancing device on page 310 Refit the balancing device to the robot 5 Detailed in section Lubrication of spherical roller bearing ba...

Page 306: ...Balancing device A Rear cover B Support shaft inside C Attachment screws rear cover D Balancing device shaft including securing screw E Bearing attachment F Parallel pin inside bearing attachment G Attachment screws bearing attachments H Continues on next page 306 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 5 4 1 Replacing the balancing...

Page 307: ...n the frame to access the balancing device shaft with the puller press tool D Locking screw attachment hole secures the lower arm to the frame E Required equipment Note Art no Spare part no Equipment Includes balancing device 3HAC020040 001 See Spare part lists on page 425 Balancing device Includes o rings 3HAB3772 44 Continues on next page Product manual IRB 6650S 307 3HAC020993 001 Revision Z Co...

Page 308: ... Lifting eye M12 3HAC 020997 1 Shackle balancing device 3HAC15556 1 Lifting tool chain 3HAC020902 001 Press tool balancing device 3HAC12475 1 Puller tool balancing device shaft 3HAC17129 1 Press tool balancing device shaft To be used with the press and puller tools 3HAC11731 1 Hydraulic cylinder 2 pcs required To be used with the hydraul ic cylinder 3HAC13086 1 Hydraulic pump 80 MPa 3HAC022643 001...

Page 309: ...307 Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out 6 Detailed in section Unloading the bal ancing device using hydraulic press tool on page 313 Shown in the figure Location of balan cing device on page 306 Remove the securing screw from the balancing device shaft 7 Art no is specified in Required equipment on page...

Page 310: ...to a secure area allowing the bearing attachments to slide on the guide pins 13 Refitting balancing device The procedure below details how to refit the balancing device Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Art no is specified in Required equipment on page 3...

Page 311: ...tion where the balancing device shaft may be inserted through the piston shaft front eye 12 Detailed in section Unloading the balancing device using hydraulic press tool on page 313 Unload the balancing device with the press tool 13 Art no is specified in Required equipment on page 307 For an easier reassembling of the shaft the piston rod may be pressed out more than necessary and then pressed in...

Page 312: ...on Restoring the balancing device using a hydraulic press tool on page 317 Restore the balancing device 18 DANGER The rear cover of the balancing device is a safety device for the piston rod during opera tion Make sure the cover is properly secured before commissioning of the robot 19 xx0300000484 Remove the locking screw that secures the lower arm to the frame 20 Attachment hole for the secur ing...

Page 313: ...is a high tensioned spring inside the balancing device incorrect handling may cause injuries and damage property Press tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 Press block A Hydraulic cylinder B Continues on next page Product ma...

Page 314: ...ent is defined in section Standard tools on page 435 Standard toolkit Using the correct press device The different designs of the balancing device require different versions of the press device included in the complete press tool The table below specifies which press device to use to which balancing device The article number of the balancing device may be found on a label at the rear of the balanc...

Page 315: ...ews DANGER DO NOT remove any other screws then the rear cover attachment screws 3 E Rear cover attachment screws 8 pcs Remove the o ring from the balancing device end the support shaft including the damper from the balancing device the remaining o ring from the balancing device end 4 Art no is specified in Required equip ment on page 314 Fit the press tool to the rear of the balancing device with ...

Page 316: ...s aligned with the hole in the frame through which the shaft may be pulled out or pressed in 9 Close the tap to the hose 10 Keep the hydraulic cylinder and pump connec ted in order to keep the balancing device un loaded in correct position 11 The hydraulic pump can be used by connect ing the second hose of the hydraulic valve to an other tool 316 Product manual IRB 6650S 3HAC020993 001 Revision Z ...

Page 317: ...ress tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 Press block A Hydraulic cylinder B Press device C Bolt press device D Moving pin with marking E Continues on next page Product manual IRB 6650S 317 3HAC020993 001 Revision Z Copyrigh...

Page 318: ...ting position 1 Remove the hydraulic cylinder 2 Shown in the figure Press tool and hydraulic cylinder on page 317 Remove the press tool by unscrewing the bolts 3 Make sure the o ring is seated prop erly Replace if damaged Lubricate and refit the o ring at the end of the balancing device 4 Make sure the damper is properly fitted to the support shaft and refit them both to the balan cing device 5 Ma...

Page 319: ...ston rod during opera tion Make sure the cover is properly secured before commissioning of the robot 8 Product manual IRB 6650S 319 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 5 4 3 Restoring the balancing device using a hydraulic press tool Continued ...

Page 320: ...dant Location of motor The motor axis 1 is located on the left hand side of the robot as shown in the figure below xx0300000499 Motor axis 1 A Motor attachment screws and washers B Required equipment Note Art no Spare part no Equipment etc Includes motor pinion o ring 21522012 430 See Spare part lists on page 425 Motor including pinion Must be replaced when reassemling the motor 21522012 430 O rin...

Page 321: ...bot These procedures include references to the tools re quired Other tools and proced ures may be required See references to these procedures in the step by step in structions below See chapter Circuit dia gram on page 441 Circuit diagram Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might ...

Page 322: ... robot Removal motor axis 1 The procedure below details how to remove motor axis 1 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 2 Remove the cover for conne...

Page 323: ...ghs 25 kg All lifting equipment used must be sized accordingly 3 Art no is specified in Required equipment on page 320 Apply the lifting tool motor axis 1 4 5 to the motor 4 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 5 Make sure the motor is turned the correct way that is connection of motorcable forwards Fit the motor making sure the moto...

Page 324: ...ed in Calibrating with Axis Calibration method on page 401 General calibration information is included in section Calibration on page 389 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 30 14 324 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB ...

Page 325: ...ing 2152 2012 430 See Spare part lists on page 425 Motor including pin ion Must be replaced when re assembling motor 21522012 430 O ring For lubricating the o ring 3HAB3537 1 Grease M16 x 60 3HAA1001 266 Locking screw For securing the lower arm Always use the removal tools in pairs 3HAC14631 1 Removal tool motor M12x For guiding the motor Guides are to be used in pairs 3HAC15521 2 Guide pins M10 x...

Page 326: ... robot These procedures include references to the tools re quired Other tools and pro cedures may be re quired See refer ences to these pro cedures in the step by step instructions below See chapter Circuit diagram on page 441 Circuit diagram Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action mi...

Page 327: ...ch calibration routine to use and take actions accordingly prior to beginning the repair proced ure 1 Shown in the figure Location of motor on page325 Move the robot to a position close enough to its calibration position to allow the lock screw to be inserted into the hole for lock screw 2 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure su...

Page 328: ...nt holes 13 Shown in the figure Location of motor on page325 Always use the removal tools in pairs Art no is specified in Required equipment on page 325 Remove the removal tools and fit the lifting tool motor axis 2 3 4 to the motor 14 CAUTION The motor weighs 32 kg All lifting equipment used must be sized ac cordingly 15 Make sure the motor pinion does not get dam aged Lift the motor to get the p...

Page 329: ...over on top of the motor and connect the 24 VDC power supply 4 Art no is specified in Required equip ment on page 325 Fit the lifting tool motor axis 2 3 4 to the motor 5 Art no is specified in Required equip ment on page 325 Fit the two guide pins in the two lower motor attachment holes 6 Shown in the figure Location of motor on page 325 CAUTION The motor weighs 32 kg All lifting equipment used m...

Page 330: ...le gland cover at the cable exit with its two attachment screws 15 Make sure the cover is tightly sealed Refit the cover on top of the motor with its four attachment screws 16 Shown in the figure Location of motor on page 325 Remove the lock screw from the hole for lock screw 17 Detailed in Performing a leak down test on page 212 Perform a leak down test 18 Detailed in the section Changing oil axi...

Page 331: ...ng 21522012 430 See Spare part lists on page 425 Motor including pinion Must be replaced when reas sembling motor 21522012 430 O ring May be used to fix axis 3 3HAC12708 1 Mechanical stop axis 3 Use attachment screws 3HAB 3409 86 M16 x 60 For lubricating the o ring 3HAB3537 1 Grease Always use the removal tools in pairs 3HAC14631 1 Removal tool mo tor M12x Continues on next page Product manual IRB...

Page 332: ...it Complete kit that also includes operating manual 3HAC15716 1 Calibration Pendu lum toolkit Required if Calibration Pendu lum is the valid calibration method for the robot Delivered as a set of calibra tion tools 3HAC055412 001 Calibration tool box Axis Calibra tion Required if Axis Calibration is the valid calibration method for the robot These procedures include ref erences to the tools requir...

Page 333: ...eference calibration routine on page 402 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Remov...

Page 334: ...nt screws and plain washers 9 Art no is specified in Required equipment on page 331 Fit the two guide pins in two of the motor attachment screw holes 10 Art no is specified in Required equipment on page 331 Press the motor out of position by fitting removal tool motor to the re maining motor attachment screw holes 11 Always use the removal tools in pairs Art no is specified in Required equipment o...

Page 335: ...800000101 Protection filter Standard 3 Tightening torque protection filter 10 Nm 10 xx1600000576 Art no is specified in Required equipment on page 331 Fit the lifting tool motor axis 2 3 4 to the motor 4 Art no is specified in Required equipment on page 331 Fit the two guide pins in the two lower motor at tachment holes 5 Shown in the figure Location of mo tor on page 331 CAUTION The motor weighs ...

Page 336: ...sure the cover is tightly sealed Refit the cable gland cover at the cable exit with its two attachment screws 15 Shown in the figure Location of mo tor on page 331 Make sure the cover is tightly sealed Refit the cover on top of the motor with its four attachment screws 16 Remove the equipment used to unload the upper arm 17 Detailed in the section Performing a leak down test on page 212 Perform a ...

Page 337: ...ming the first test run These are further detailed in the section First test run may cause injury or damage on page 30 21 Product manual IRB 6650S 337 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 6 3 Replacement of motor axis 3 Continued ...

Page 338: ...page 425 Motor including pinion Must be replaced when reas sembling motor 21522012 430 O ring 3HAC14459 1 Lifting tool motor ax 1 4 5 3HAC15534 1 Lifting tool motor ax 2 3 4 Used to lubricate the o ring 3HAB3537 1 Grease Option Foundry Plus 12340011 116 Loctite 574 Flange sealant Always use the removal tools in pairs 3HAC14972 1 Removal tool motor M10x For guiding the motor 3HAC15520 1 Guide pins ...

Page 339: ...n might be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence...

Page 340: ...gland cover at the cable exit of the motor by unscrewing its two at tachment screws 4 Make sure the gasket is not damaged Remove the cover on top of the motor by unscrewing its four attachment screws 5 Disconnect all connectors beneath the motor cover 6 Connect to connector R2 MP4 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 7 Shown in the figure Location of motor on p...

Page 341: ...art delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Standard 3 Tightening torque protection filter 10 Nm 10 xx1600000576 Connect to connector R2 MP4 pin 2 pin 5 In order to release the brakes connect the 24 VDC power supply 4 Art no is specified in Required equip ment on page 338 Fit the tw...

Page 342: ...four attachment screws 12 Shown in the figure Location of motor on page 338 Refit the cable gland cover at the cable exit with its two attachment screws 13 Detailed in the section Performing a leak down test on page 212 Perform a leak down test if the gearbox has been drained 14 Detailed in the section Filling oil on page 184 Refill the gearbox with oil if drained 15 Pendulum Calibration is descri...

Page 343: ...200000204 Motor axis 5 A Upper arm tube B Wrist unit C Required equipment Note Art no Equipment etc Does not include pinion Use the pin ion from the motor to be replaced For spare part number see Spare part lists on page 425 Motor Includes o ring 21522012 430 Used to obtain the correct distance between motor flange and outer sur face of motor pinion 3HAC7941 28 Set of shim motor Must be replaced w...

Page 344: ...d prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routi...

Page 345: ...etailed in the section Changing oil axis 5 gearbox on page 186 Drain the oil from gearbox axis 5 3 Detailed in the section Removal wrist unit on page 260 xx1400002580 Remove the wrist unit 4 Place the wrist unit safely on a workbench in a fixture or similar 5 Remove the cover on top of the motor by unscrew ing its four attachment screws 6 Remove the cable gland cover at the cable exit by unscrewin...

Page 346: ...equired equipment on page 343 Measure the distance between the motor flange included eventual shims and the outer surface of the pinion with measuring tool 15 Make a note of the distance Replacing the complete wrist unit is detailed in section Replacement of complete wrist unit on page 258 Press out the pinion from the dismounted motor with the equipment included in the oil injector kit Note If th...

Page 347: ...o ob tain the same distance as measured when dismounting the old motor 0 0 05 mm Connect to either In order to release the brake connect the 24 VDC power supply 8 connector R4 MP5 in the motor pin 2 pin 5 connector R3 MP5 on the separate cable if not removed pin C pin D Art no is specified in Required equip ment on page 343 Fit the two guide pins in two of the motor attach ment holes 9 Make sure t...

Page 348: ...Operating manual Calibration Pendu lum enclosed with the calibration tools Re calibrate the robot 21 Axis Calibration is described in Calib rating with Axis Calibration method on page 401 General calibration information is in cluded in section Calibration on page 389 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First ...

Page 349: ...quipment Note Art no Spare part no Equipment etc Includes motor pinion o ring 21522012 430 See spare part number in Spare part lists on page 425 Motor including pinion Must be replaced when reas sembling motor 21522012 430 O ring Continues on next page Product manual IRB 6650S 349 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 6 6 Replacement of motor axis 6 ...

Page 350: ...g manual 3HAC15716 1 Calibration Pendulum toolkit Required if Calibration Pendu lum is the valid calibration method for the robot Delivered as a set of calibra tion tools 3HAC055412 001 Calibration tool box Axis Calibration Required if Axis Calibration is the valid calibration meth od for the robot These procedures include references to the tools re quired Other tools and proced ures may be requir...

Page 351: ...eference calibration routine on page 402 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Remov...

Page 352: ... refit motor axis 6 Note Robots with protection type Foundry Plus or Foundry Prime require special repair routines to maintain the tightness level in addition to the procedure below described in Replacement of the motor axis 6 Foundry Plus on page 353 Note Action Art no is specified in Required equipment on page 349 Make sure the o ring on the circumference of the motor is seated properly Lightly ...

Page 353: ...n First test run may cause injury or damage on page 30 11 Replacement of the motor axis 6 Foundry Plus Robots with protection type Foundry Plus require special repair routines to maintain the tightness level The repair must be done according to the previous repair procedure with the following additions Note Action Move the robot to a position where the motor in axis 6 is pointed straight up This p...

Page 354: ...Rear motor cover E Gasket Continue to remove the motor unit according to step 6 and forwards in Removal motor on page 351 4 Note Keep the old rear motor cover with the air nipple 5 Continues on next page 354 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 6 6 Replacement of motor axis 6 Continued ...

Page 355: ...over H Sealing J Loctite 574 Apply Mercasol 3106 on the motor end cover 7 xx1400000992 Apply Loctite 574 flange sealant on the contact surface 8 Apply grease on the o ring on the motor 9 Continue to refit the new motor according to section Refitting motor on page 352 10 Product manual IRB 6650S 355 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 6 6 Replacement of ...

Page 356: ... Equipment etc Includes gearbox all o rings and seal ing rings For spare part no see Spare part lists on page 425 Gearbox Replace if damaged 3HAB3772 54 O ring Replace if damaged 3HAB3772 55 O ring Replace if damaged 3HAC11581 4 Sealing ring For lubricating the o rings 3HAB3537 1 Grease Continues on next page 356 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights...

Page 357: ...hese procedures include references to the tools re quired Other tools and pro cedures may be re quired See refer ences to these pro cedures in the step by step instructions below Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair work of the robot ...

Page 358: ...he robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removal gearbox axis 1 Use this procedure to remove gearbox axis 1 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 xx0300000632 Move the robot to its most stable position shown in the figure to the right ...

Page 359: ...ed equip ment on page 356 Lift the robot base including the axis 1 gearbox to allow the base and gear 1 sup port be fitted on each sides of the base 9 xx1000000364 A Support base 4 pcs Secure the support to the base and to the foundation Make sure the base remains in a stable position before performing any work under neath the base 10 Continues on next page Product manual IRB 6650S 359 3HAC020993 ...

Page 360: ...Bottom plate B Rear connector plate C Attachment screw D Groove xx0200000227 A view from below A Oil drain hose B Attachment screws gearbox axis 1 18 pcs C Washers 3 pcs Unscrew the attachment screws and re move the washers 12 Continues on next page 360 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continu...

Page 361: ...gly 14 Lift the gearbox away with the already mounted lifting tools 15 xx1400000786 Turn the gearbox and remove the protec tion pipe by unscrewing two attachment screws Note Move the protective pipe over to the new gearbox 16 Continues on next page Product manual IRB 6650S 361 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continue...

Page 362: ... no is specified in Required equip ment on page 356 xx0200000055 A Guide pin C O ring 3HAB 3772 54 D O ring 3HAB 3772 55 E Sealing ring 3HAC 11581 4 Make sure the two o rings on the circumfer ence of the gearbox are seated properly in their respective groove Lubricate them with grease 2 Continues on next page 362 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights...

Page 363: ...in to the gearbox 4 Specified in Required equipment on page 356 Fit two guide pins in two of the attachment holes in the gearbox parallel to each other 5 CAUTION The gearbox weighs 200 Kg All lifting accessories used must be sized ac cordingly 6 Continues on next page Product manual IRB 6650S 363 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axi...

Page 364: ...th the base 7 xx1000001391 Always use guide pins in pairs Lift gearbox axis 1 onto the guide pins and lower it carefully to its mounting position 8 Continues on next page 364 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 365: ...n Screw joints on page431 before fit ting xx0200000227 A view from below A Oil drain hose B Attachment screws gearbox axis 1 18 pcs C Washers 3 pcs xx1000001393 Refit the cable guide in the center of gearbox 1 with its attachment screws 10 Continues on next page Product manual IRB 6650S 365 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 ge...

Page 366: ...n section Refitting arm sys tem on page 252 Refit the complete arm system CAUTION This is a complex task to be performed with utmost care in order to avoid injury or dam age 15 See section Performing a leak down test on page 212 Perform a leak down test 16 See Changing oil axis 1 gearbox on page 174 Refill the gearbox with oil 17 Pendulum Calibration is described in Operating manual Calibration Pe...

Page 367: ...ming the first test run These are further detailed in the section First test run may cause injury or damage on page 30 19 Product manual IRB 6650S 367 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 368: ...0000546 Gearbox axis 2 inside the frame A Attachment hole for the locking screw lower arm B Attachment holes inside of frame for the fixture lower arm C Attachment holes for the fixture lower arm D Motor axis 2 E Rear attachment screws gearbox F Cover axis 2 G Attachment screws cover H Continues on next page 368 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights ...

Page 369: ...aulic pump when unloading the balancing device 3HAC11731 1 Hydraulic cylinder To be used with the press tool and the hydraulic cylinder when unload ing the balancing device 3HAC13086 1 Hydraulic pump 80 MPa For guiding the sealing 3HAC14628 1 Guide pins sealing ax 2 3 80mm For guiding the sealing 3HAC14628 2 Guide pins sealing ax 2 3 100mm Used to turn the gear in correct po sition 3HAC020999 001 ...

Page 370: ...ous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removal gearbox axis 2 The procedure below details how to...

Page 371: ...sing the gearbox out Art no is specified in Required equipment on page 369 Fit two guide pins in 180 relation to each other in the empty holes of the front gearbox attachment screws 10 If required apply two M12 screws to the holes shown in the figure above to press it free 11 Art no is specified in Required equipment on page 369 Fit the lifting tool gearbox axis 2 to the gearbox 12 CAUTION The gea...

Page 372: ...551 Make sure the o ring is fitted to the gearbox as shown in the figure to the right Lightly lubricate it with grease 2 A O ring gearbox axis 2 Art no is specified in Required equip ment on page 369 Fit the lifting tool gearbox axis 2 to the gear box 3 Art no is specified in Required equip ment on page 369 Fit the new sealing axis 2 3 to the gearbox 4 Continues on next page 372 Product manual IRB...

Page 373: ...ent on page 369 xx0300000554 Fit two guide pins M12 in 180 relation to each other in the frame in the screw holes for the gearboxes front attachment screws 6 A Attachments in the frame for the two guiding pins CAUTION The gearbox weighs 100 kg All lifting equip ment used must be sized accordingly 7 Lift the gearbox to its mounting position and slide it onto the guiding pins attached in the frame t...

Page 374: ...the figure Location of gear box on page 368 Insert and secure 16 of the 18rear attachment screws gearbox on the inside of the lower arm 15 18 pcs M16 x 50 tightening torque 300 Nm Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page 431 before fitting Remove the guide pins sealing axis 2 3 and tighten the two remaining screws as detailed above 16 Det...

Page 375: ...n page 401 General calibration information is in cluded in section Calibration on page 389 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 30 26 Product manual IRB 6650S 375 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 2 Replacement o...

Page 376: ...pare parts IRB 7600 xx0200000194 Gearbox axis 3 A Motor axis 3 B Upper arm C Attachment screws M12x60 quality Gleitmo 24 pcs D Required equipment Note Art no Equipment etc Includes gearbox o ring Does not include the seal ing axis 2 3 For spare part num ber see Spare part lists on page 425 Gearbox Continues on next page 376 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB...

Page 377: ...aling ax 2 3 80mm Use guides in pairs For guiding the axis 3 sealing 3HAC14628 2 Guide pins sealing ax 2 3 100mm Use guides in pairs Content is defined in sec tion Standard tools on page 435 Standard toolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum toolkit Required if Calibration Pendulum is the valid cal ibration method for the ro bot Delivered as a set o...

Page 378: ...ore about reference calibration for Axis Calibration in Reference calibration routine on page 402 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all externa...

Page 379: ...axis 2 3 between the gearbox and lower arm 6 Place the upper arm safely on a workbench in a fixture or similar 7 Shown in the figure Location of gearbox on page 376 Remove the attachment screws gearbox 8 Art no is specified in Required equipment on page 376 Fit the two guide pins in 180 rela tion to each other in the gearbox attachment screw holes 9 xx0900000113 Fit the Lifting accessory RV2 ac co...

Page 380: ...the gearbox with guid ance from the guide pins using an overhead crane or similar 13 Refitting gearbox axis 3 The procedure below details how to refit gearbox axis 3 Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot work ing area 1 Turn the upper arm in such a position that the gear m...

Page 381: ...g accessory RV2 ac cording to figure 5 Art no is specified in Required equipment on page 376 xx0200000173 Make sure the o rings are fitted to the gearbox Apply grease to the o rings to make sure they stick in their grooves during as sembly Replace if damaged 6 A O ring gearbox axis 3 Lift the gearbox to its mounting position 7 Continues on next page Product manual IRB 6650S 381 3HAC020993 001 Revi...

Page 382: ...efit the upper arm with a new sealing axis 2 3 12 Detailed in section Refitting upper arm on page 270 Detailed in section Refitting motor on page 335 Refit the motor 13 Pendulum Calibration is described in Operating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 14 Axis Calibration is described in Calibrating with Axis Calibration method on page 401 General c...

Page 383: ...ng D O ring not shown in figure Required equipment Note Article number Equipment etc Includes o ring For spare part number see Spare part lists on page 425 Gearbox Not included in gearbox 3HAA1001 172 Washers Replace when damaged Must be replaced when reas sembling gearbox 3HAB3772 58 O ring Continues on next page Product manual IRB 6650S 383 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All r...

Page 384: ... Calibration Required if Axis Calibration is the valid calibration method for the ro bot These procedures include refer ences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which rou...

Page 385: ... the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removal gearbox The procedure below details how to remove gearbox axis 6 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 DANGER Turn off all electric power supply to the robot hydraulic pressure supply ...

Page 386: ...ge the motor pinion Remove the gearbox axis 6 by lifting it out carefully 7 Refitting gearbox The procedure below details how to refit gearbox axis 6 Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the ro bot air pressure supply to the robot Before entering the robot working area 1 Continues on next page 386 Product manual IRB 6650S 3HAC020993 001 Re...

Page 387: ...Shown in the figure Location of gearbox on page 383 Make sure the gears of the gearbox mate with the gears of the motor Shown in the figure Location of gearbox on page 383 Secure the gearbox with the attachment screws and washers 6 8 pcs or 18 pcs depending on wrist ver sion M8 x 40 12 9 quality Gleitmo Tight ening torque 30 Nm Reused screws may be used providing they are lubricated as detailed in...

Page 388: ...brate the robot 10 Axis Calibration is described in Calibrating with Axis Calibration method on page 401 General calibration information is included in section Calibration on page 389 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 30 11 388 Product manual IRB 6650S 3HAC0...

Page 389: ...t is used for calibration of the robot Calibration position A generic term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can...

Page 390: ...in the Cartesian coordinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The file replaces the calib cfg file and identifies motor positions a...

Page 391: ...ugh the calibration procedure step by step 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 wi...

Page 392: ...or the calibration tools are listed in the section Special tools on page 436 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit including the Operating manual Calibration Pendulum which describes the method and the different routines further 392 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 5 Calibration 5 1 2 Cali...

Page 393: ...nter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 396 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and con...

Page 394: ...ater design B2 Synchronization mark axis 3 early design C1 Synchronization mark axis 3 later design C2 Synchronization mark axis 4 D Synchronization mark axis 5 E Synchronization mark axis 6 F Synchronization marks at axes 2 and 3 The synchronization marks at axes 2 3 and 6 shown in the figure above consist of two single marks that should be positioned opposite to one another when the robot is sta...

Page 395: ...es will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 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 395 3HAC020993 001 Rev...

Page 396: ...can be calibrated at the wrong turn resulting in an incorrect manipulator calibration Make sure the axes are positioned according to the correct calibration values not only according to the synchronization marks The correct values are found on a label located either on the lower arm underneath the flange plate on the base or on the frame At delivery the manipulator is in the correct position do NO...

Page 397: ...d unit and choose Rev Counter Update from the Calib menu The Revolution Counter Update window appears xx0100000202 3 Select the desired axis and press Incl to include it it will be marked with an x or press All to select all axes 4 Press OK when all axes that are to be updated are marked with an x CANCEL returns to the Calibration window 5 Press OK again to confirm and start the update CANCEL retu...

Page 398: ...y carefully after each update 8 How to perform the check is detailed in section Checking the synchron ization position on page 414 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 1 Continues on next page 398 Product manual IRB 6650S 3HAC020993 001 Revision Z...

Page 399: ...RobotWare 6 02 and later 3 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 399 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 400: ...s displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn ma...

Page 401: ...able calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the 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 inser...

Page 402: ...the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Note When calibrating the robot with the reference calibration routine the robot must be dressed with the same tools process cabling and any other equipment as when the reference values were created Update revolution counters Choose this routine to ma...

Page 403: ...gs may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection ...

Page 404: ...olution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavit...

Page 405: ...hes are fitted to the robot Keep the tower in a safe location for future recalibration needs and mark it with robot serial number to ensure that the correct one is refitted Spare parts When calibration is not being performed a protective cover and an o ring should always be installed on the fixed calibration pin as well as a protective plug included a sealing in the bushing Replace damaged parts w...

Page 406: ...re on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a brief overview of the calibration procedure sequence ...

Page 407: ...nt while conducting it Note Action DANGER While conducting the calibration the robot needs to be connected to power Make sure that the robots working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use ...

Page 408: ... the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 406 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and ...

Page 409: ...libration SafeMove needs to be unsynchronized The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine Safety controller not synchronized SafeMove message Note Action SafeMove generates the message Safety control ler not synch...

Page 410: ...Unsynchronized time limit expired SafeMove message anytime during Axis Calibration routine Note Action SafeMove generates the message Unsynchron ized time limit expired anytime xx1500002482 1 Press OK to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page 410 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB Al...

Page 411: ...ction cover and plug set 3HAC056806 001 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC056806 001 Product manual IRB 6650S 411 3HAC020993 001 Revision Z Copyright 2004 20...

Page 412: ...dulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools 412 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 413: ...hange the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 394 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm Remove any calibration equipment fro...

Page 414: ...ck that the synchronization marks for the axes align correctly If they do not update the revolution counters 3 Using a MoveAbsJ instruction Use this procedure to create a program that runs all the robot axes to their synchronization position Note Action On ABB menu tap Program editor 1 Create a new program 2 Use MoveAbsJ in the Motion Proc menu 3 Create the following program MoveAbsJ 0 0 0 0 0 0 9...

Page 415: ...ers 4 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis 1 2 or 3 3 Manually run the robots axes to a position where the axis position value read on the FlexPendant is equal to zero 4 See Synchronization marks and synchr...

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Page 417: ...s Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance ...

Page 418: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 418 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 419: ...ttery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire 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 419 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All r...

Page 420: ...nces deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balancing device is potentially lethal Action on field decommissioning The procedure below details the actions to perform on field when the balancing device is to be decommissioned Note Action Detailed in section Removal balancing device on page 309 Remove the bal...

Page 421: ...or similar 2 Use a cutting torch The measurements shown below are maximum values xx0400000698 Open a hole in the side of the housing as shown in the figure 3 Use a cutting torch Cut the coils of the three springs inside the housing as specified below Outer spring cut at least five coils Middle spring cut at least four coils Inner spring cut at least four coils 4 Double check the number of coils cu...

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Page 423: ...robot axis by article number The article numbers specified are found in WebConfig Contact ABB Service for further assistance regarding which motor type is installed on the robot if needed Note 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 Arti...

Page 424: ... motors are interchangeable on each robot axis Requirements notes for replacing type A motor with type B motor Motor replacement from type A to type B Robot axis Fully interchangeable 1 Fully interchangeable 2 Fully interchangeable 3 Fully interchangeable 4 Fully interchangeable 5 Fully interchangeable 6 424 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights rese...

Page 425: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 6650S 425 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 8 Spare part lists 8 1 Spare part lists and illustrations ...

Page 426: ...This page is intentionally left blank ...

Page 427: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 6650S 427 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 9 Reference information 9 1 Introduction ...

Page 428: ...15i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment of...

Page 429: ...R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 6650S 429 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 9 Reference information 9 2 Applicable standards Continued ...

Page 430: ...9 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 430 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 9 Reference information 9 3 Unit conversion ...

Page 431: ...ld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions ...

Page 432: ...air maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The ...

Page 433: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 6650S 433 3HAC020993 001 Re...

Page 434: ...ory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 2275 kg All lifting accessories used must be sized accord ingly 434 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB...

Page 435: ...on Contents standard toolkit Rem Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm 1 Hex bit...

Page 436: ... 1 Lifting tool motor ax 2 3 4 3HAC14972 1 2 Removal tool motor M10x Fits motors axes 4 5 and 6 3HAC14631 1 2 Removal tool motor M12x Fits motors axes 1 2 and 3 3HAC17105 1 1 Rotation tool 3HAC12708 1 2 Mechanical stop axis 3 3HAB3409 86 2 Bolts M16 x 60 for mechanical stop axis 3 3HAA1001 186 2 Washers for mechanical stop axis 3 3HAC15571 1 1 Standard toolkit content described in section Standard...

Page 437: ...96134 GN 1 Measuring tool 3HAC021590 001 1 Oil injector max 500 MPa 3HAC13527 1 1 Press tool axis 2 bearing 3HAC021563 001 1 Puller device axis 2 shaft 3HAC021600 001 1 Press device axis 2 shaft 3HAC020902 001 1 Press tool balancing device 3HAC17129 1 1 Press tool balancing device shaft 3HAC12475 1 1 Puller tool balancing device shaft 3HAC020997 001 1 Shackle balancing device 3HAC15535 1 1 Support...

Page 438: ...dant If no data is found related to standard calibration Calibration Pendulum is used as default Note Art no Description Complete kit that also includes operating manual 3HAC15716 1 Calibration Pendulum toolkit Calibration equipment Axis Calibration The following table specifies the calibration equipment needed when calibrating the robot with the Axis Calibration method The robot is calibrated by ...

Page 439: ... pump with regulator hose and coupling Couplings and adapters Pump manual with hose and coupling Graduated measuring glass Oil gun User instructions 3HAC021745 001 Oil exchange equipment Product manual IRB 6650S 439 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 9 Reference information 9 7 Special tools Continued ...

Page 440: ...ing accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference 440 Product manual IRB 6650S 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved 9 Reference information 9 8 Lifting accessories and lifting ...

Page 441: ... 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 2...

Page 442: ... diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 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 Decide which circuit diagram is valid for the robot by ...

Page 443: ... fitted to the robot and see page 3 of the circuit diagram in order to determine if the diagram is valid for the harness or not Action Where to find the article number The label is located at the connectors in the base Remove the rear cover plate to see the label Label on the cable harness WebConfig Product manual IRB 6650S 443 3HAC020993 001 Revision Z Copyright 2004 2018 ABB All rights reserved ...

Page 444: ... in the base Remove the rear cover plate to see the label Label on the cable harness WebConfig This circuit diagram is valid for the following cable harness assemblies Revision Cable harness Robot all 3HAC 14940 1 IRB 6600 all 3HAC 16331 1 IRB 6650 IRB 6650S revision 0 2 3HAC 14940 1 IRB 7600 For remaining cable harness assemblies see section Validity of circuit diagram 3HAC025744 1 on page 443 44...

Page 445: ...91 Levelmeter calibration 391 rough 396 standard type 390 verification 413 when to calibrate 393 calibration Absolute Accuracy 391 calibration manuals 392 calibration marks 394 calibration position jogging to 415 jogging to TPU 415 scales 394 calibration scales 394 CalibWare 390 carbon dioxide extinguisher 24 cast iron disposal 417 changing oil axis 1 174 cleaning 199 climbing on robot 27 Cold env...

Page 446: ...ng accessory 264 limitation of liability 21 Lithium disposal 417 loads on foundation 53 lower arm dimensions 81 replacement 273 lower arm shaft replacement 283 lubrication amount in gearboxes 172 type of lubrication 172 M magnesium disposal 417 maintenance schedule 127 manually releasing brakes 70 mechanical stop axis 1 99 axis 2 102 axis 3 104 mechanical stop location 161 motion of axes 59 motor ...

Page 447: ...on robot 44 test run 30 working range 31 safety equipment mechanical stop 99 mechanical stop axis 2 102 mechanical stop axis 3 104 position switches 107 signal lamp 170 safety fence 22 safety risk electric parts 33 hot parts 36 hydraulic system 37 installation 27 oil change 40 operational disturbance 27 pneumatic system 37 service work 27 voltage 33 safety signals in manual 42 safety standards 428...

Page 448: ...revolution counters 396 upper arm dimensions 83 replacement 264 V validity and responsibility 21 velocity adjusting 124 verifying calibration 413 W weight 53 balancing device 309 311 base plate 72 77 gearbox 371 373 380 381 lower arm 279 280 motor 323 334 335 robot 65 66 69 359 361 363 366 434 upper arm 269 270 wrist unit 261 working range 56 restricting axis 1 99 restricting axis 2 102 restrictin...

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Page 450: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC020993 001 Rev Z en Copyright 2004 2018 ABB All rights reserved Specifications subject to change without notice ...

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