Page 1 ROBOTICS Product manual IRB 6620...
Page 2 Trace back information: Workspace 20B version a14 Checked in 2020-05-29 Skribenta version 5.3.033...
Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Installation of Foundry Plus Cable guard (option no. 908-1) ......Electrical connections ..................2.8.1 Robot cabling and connection points ............Start of robot in cold environments ..............Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 6 Replacement of motor axis 2 ..............4.6.3 Replacement of motor, axis 3 ..............4.6.4 Replacement of motor, axis 4 ..............4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX ........... Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 7 Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare part lists Spare part lists and illustrations ................Circuit diagram Circuit diagrams ....................Index Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
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Page 9: Overview Of This Manual
ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 6620. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 3HAC025861-001 Product manual, spare parts - IRB 6620 3HAC049109-001 Product manual - DressPack/SpotPack IRB 6620 3HAC027309-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Safety manual for robot - Manipulator and IRC5 or OmniCore 3HAC031045-001 controller Product manual - IRC5 3HAC021313-001 IRC5 with main computer DSQC 639.
Page 11 118. • Corrected item number reference in part list, see Spare parts - Upper arm in Product manual, spare parts - IRB 6620. • Circuit diagrams are not included in this document but delivered as separate files. See Circuit diagram on page 347.
Page 12 New wrist cover and improved sealing on arm house cover, and more. • Minor corrections. This revision includes the following updates: • Minor corrections. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 13 Note added about the need to calibrate if the robot is other than floor mounted. See When to calibrate on page 303. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 14 Clarified text about position of robot and added table with dependencies between axes during Axis Calibration. • Added information about Wrist Optimization in calibration chapter. • Replaced article number and name of grease, previously 3HAB3537-1. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 15: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 16 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 17: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
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Page 19: Safety
The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.
Page 20: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the product manual. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 21: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 22 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 23: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 24 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 25 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 26 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 27 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 28 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 29: Robot Stopping Functions
The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 • Product manual - IRC5 Panel Mounted Controller Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 30: Installation And Commissioning
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Electrical safety The mains power must be installed to fulfill national regulations. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 31 The risk assessment should also consider other hazards, such as, but not limited • Water • Compressed air • Hydraulics Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 32 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 33: Operation
Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 35 Operating temperatures are listed in Operating conditions, robot on page See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 36 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 37: Emergency Release Of The Robot Axes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 38: Brake Testing
3 Inspect and verify that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 39: Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 40: Decommissioning
Never stay beneath a robot arm. Gravity and the release of braking devices can create additional hazards. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 41: Installation And Commissioning
Note If the IRB 6620 is connected to power, always make sure that the robot is connected to protective earth and a residual current device (RCD) before starting any installation work. For more information see: •...
Page 42: Robot Transportation Precautions
Pre-installation procedure on page 51 Method 2 - transportation with a tool mounted to the robot Transportation according to method 2 is approved by ABB, only if use of method 1 is not possible. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W ©...
Page 43 Always read and follow the instructions in section Securing the robot with a transport support on page 48 • Always place the robot in the ABB recommended transport position for robot with tool, described in sub section Transport position with a transport support on page •...
Page 44 2.2 Robot transportation precautions Continued IRB 6620 xx0800000036 Transport Support Hexagon socket head cap screw M10x50 Threaded bar M10x280 Nut M10 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 45 Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 6620 xx0800000041 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 46 2.2 Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 6620 xx0800000039 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 47 2 Installation and commissioning 2.2 Robot transportation precautions Continued IRB 6620 xx0800000038 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 48: Securing The Robot With A Transport Support
Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 49 See attachment point for the specific ro- (A) in figure. bot in the section Transport position with a transport support on page Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 50 Use the brake release for axis 5 and 6 to reach the final resting position for the tool, see the section Manually releasing the brakes on page 74 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 51: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 52 These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 53 Maximum tilt 15° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W...
Page 54 Protection class Manipulator, protection type Standard IP 54 Manipulator, protection type Foundry Plus IP 67 The upper arm, including the wrist, has protection class IP 67. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 55: Working Range And Type Of Motion
Floor mounted The illustration below shows the unrestricted working range when the robot is floor mounted: 8 58 1473 2204 xx0600002906 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 56 2.4.2 Working range and type of motion Continued Suspended mounted The illustration below shows the unrestricted working range when the robot is mounted suspended: 2204 1473 xx0600002907 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 57 15° angle: 1019 1171 2369 xx0600002908 Note! Maximum tilt angle is 15° Intersection between base and axis 1 center Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 58 + 300° to - 300° default Max. ±96 revolutions ¹ ¹ The default working range can be extended by changing parameter values in the software. OptionAdvanced Motion is required. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 59: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx0600002935 WARNING The robot will be mechanically unstable if not properly secured to the foundation. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 60: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 61: On-Site Installation
If the robot is dressed, this must be taken into consideration when the robot is be- ing lifted. xx0600002935 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 62 The fork lift accessory is fitted on the robot as shown in the figure. xx0600002910 Fork lift pocket Attachment screw M20x60 quality 8.8 (2 pcs x4) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 63 A Fork lift pocket (4 pcs) B Attachment screw M20x60 quality 8.8 (2 pcs x4) Verify that all four fork lift pockets are properly secured before lifting. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 64: Lifting The Robot With Fork Lift Truck
Verify that all four fork lift pockets are properly secured before lifting. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 65 If lifting with fewer than four fork lift pockets fitted, there is a risk of accidents! xx0600002911 IRB 6640 xx0600003401 IRB 460 xx1000001159 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 66 Continued Action Note Remove the attachment bolts securing the robot to the foundation. CAUTION The IRB 6620 robot weighs 900 kg. All lifting accessories used must be sized accordingly! Carefully lift the robot. WARNING Personnel must not, under any circum-...
Page 67: Lifting The Robot With Lifting And Turning Tool
The lifting and turning tool 3HAC025792-001is used for lifting and turning of the IRB 6620. xx0900000325 Upper lifting beam Chains Lifting eye Lower lifting beam Lifting hold (Left and Right) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 68 Lifting position xx0900000330 Action Note Jog the robot axis to a posi- Lifting position according to figure. tion suitable for lifting Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 69 Lifting eye upper beam Attachment bolts in robot base Distribution beam Attachment bolts for distribution beam Lifting chains Chain block lifting eye Upper beam Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 70 Note Use a suitable chain block for minimum lifting weight 500 kg and with chain length minimum 3 m. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 71 350 mm. Turn the robot using the chain block. If the robot is to be moved to the installation location, use a forklift. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 72: Lifting Robot With Roundslings
2, in order not to dam- age the harness! CAUTION The IRB 6620 robot weighs 900 kg. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W ©...
Page 73 Roundsling upper arm, 2 m. Roundsling robot, 2.5 m (4 pcs). Lifting eye, M20 (4 pcs) Holes for lifting eyes in the robotbase. (Rear holes) Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 74: Manually Releasing The Brakes
Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 75 Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 76: Lifting The Base Plate
Fit lifting slings to the eyes and to the lifting accessory. CAUTION Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 77: Securing The Base Plate
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 78 2 Installation and commissioning 2.5.6 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 79 The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate. xx1500000312 Orienting grooves (3 pcs) Levelling bolts, attachment holes (4 pcs) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 80 Base plate This section details how to secure the base plate to the foundation. Action Note Make sure the foundation is levelled. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 81 0.3 mm. If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 82: Orienting And Securing The Robot
M24 x 100 Quality: Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 83 Note Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 84 2.5.7 Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. R400 xx0600002932 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 85 2 Installation and commissioning 2.5.7 Orienting and securing the robot Continued Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0600002934 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 86: Setting The System Parameters For A Suspended Or Tilted Robot
The Gravity Beta is a positive rotation direction around the y-axis in the base coordinate system. The value is set in radians. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 87 Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Tilted mounting 15° 0.261799 Suspended mounting 180° 3.141593 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 88 Examples of mounting angles tilted around the Y axis (Gravity Beta) xx0600003144 Floor mounted Tilted mounting, mounting angle 15°. Suspended mounting, mounting angle 180°. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 89 90° (Wall) 1.570796 -90° (Wall) -1.570796 Note For suspended robots (180°), it is recommended to use Gravity Beta instead of Gravity Alpha. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 90 Mounting angles and values on page The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 91: Fitting Equipment On Robot
Make sure not to damage the robot cabling on the lower arm when fitting extra equipment. Always use appropriate attachment screws! xx0600002940 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 92 2 Installation and commissioning 2.5.9 Fitting equipment on robot Continued xx0600002944 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 93 Illustration, fitting of extra equipment on upper arm The illustrations below shows the mounting holes available for fitting extra equipment on the upper arm. xx0600002941 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 94 2 Installation and commissioning 2.5.9 Fitting equipment on robot Continued xx0600002945 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 95 Illustration, fitting of extra equipment on frame The mounting holes available for fitting extra equipment on the frame are shown below. xx0600002947 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 96 2 Installation and commissioning 2.5.9 Fitting equipment on robot Continued xx0600002950 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 97 Turning disk for robot version IRB6620 - 150/2.2. Use every other of the bolt holes for six attachment bolts, as numbered in the figure. Turning disk type 1 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 98 2 Installation and commissioning 2.5.9 Fitting equipment on robot Continued xx0200000197 Turning disk (type 2) for robot version IRB 6620 Foundry Plus. Fastener quality When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9.
Page 99: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 100: Signal Lamp (Option)
The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 101: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 102: Mechanically Restricting The Working Range Of Axis 1
Movable mechanical stop Attachment screw plus washer, M12 x 40 quality 12.9 (2 pcs) Fixed mechanical stop Mechanical stop pin axis 1 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 103 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 104: Mechanically Restricting The Working Range Of Axis 3
• document for Mech stop pin, 3HAC025409-001. Standard toolkit Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 105 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 106: Foundry Plus Cable Guard (Option)
Separate instructions for IRB 140, 4600, 1600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found on the DVD delivered with the Cable guard, article number 3HAC035933-001. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 107: Electrical Connections
DressPack cables (option) Handles signals, process media and power feeding for customer use, regarding material handling or spot welding. See the Product manual - DressPack/SpotPack IRB 6620, see document number in References on page Robot cables These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.
Page 108 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx1500001603 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 109 2 Installation and commissioning 2.8.1 Robot cabling and connection points Continued Note How to ground DressPack/SpotPack cables is detailed in the Product manual - DressPack/SpotPack IRB 6620, see the document number in References on page Product manual - IRB 6620 3HAC027151-001 Revision: W...
Page 110: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 111: Maintenance
Note If the IRB 6620 is connected to power, always make sure that the IRB 6620 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: •...
Page 112: Maintenance Schedule And Expected Component Life
40000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.
Page 113: Maintenance Schedule
The following table specifies the required maintenance activities and intervals. Maintenance activity Equipment Interval Cleaning Robot Cleaning the IRB 6620 on page 168 Inspection Oil level in axis-1 gearbox Every 12 months. Inspection Oil level in axis-2 gearbox Every 12 months.
Page 114 Maintenance activity Equipment Interval Note Inspection Signal lamp Every: 12 months Inspection Mechanical stop axis 1 Every: and 3 12 months Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 115: Expected Component Life
5 is not calculated by SIS (See the Operating manual - Service Information System). In some applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB Robotics Service team for more information.
Page 116: Inspection Activities
Use this procedure to inspect the oil level in the axis-1 gearbox. Action Note WARNING Handling gearbox oil involves several safety risks, Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 117 Further information about how to fill with oil is found in section Changing oil, axis-1 gearbox on page 147. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 118: Inspecting The Oil Level In Axis-2 Gearbox
The following figure shows suspended mounted robot. The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0600002960 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 119 Open the oil plug, filling and inspection. Shown in the figure Location of gear- box on floor mounted robot on page 118. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 120 145. Filling of oil is detailed further in the section Filling, oil on page 151. Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 121: Inspecting The Oil Level In Axis-3 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 122 Further information about how to fill the oil may be found in the section Filling, oil on page 154. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 123: Inspecting The Oil Level In Axis-4 Gearbox
Use this procedure to inspect the oil level in the axis-4 gearbox. Action Note WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 124 Further information about how to fill the oil may be found in the section Filling, oil on page 157. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 125: Inspecting The Oil Level In Axis-5 Gearbox
Move the robot upper arm to a horizontal position. Turn the wrist unit in a way that both oil plugs are facing upwards. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 126 Further information about how to fill the oil may be found in the section Filling, oil, axis 5 on page 160. Refit the oil plug. Tightening torque:24 Nm Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 127: Inspecting The Oil Level In Axis-6 Gearbox
Move axes 3 and 5 to a horizontal position, and make sure that the oil plug, filling and inspection is facing upwards. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 128 This will avoid surface tension from stopping air to enter into the gearbox. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 129 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 130: Inspecting, Cable Harness
SMB/BU box Top cover, connection box Connection plate, base Connector R1.SMB Connector R1.MP Metal clamps Cable harness Cable guide (cut away view) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 131 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 132 Detailed in section: is detected! Replacement of cable harness, lower end (axes 1-2) on page 180 Replacement of cable harness, upper end on page 187 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 133: Inspecting The Information Labels
Warning sign, symbol of a flash (located on motor cover) (5 pcs) Warning label concerning brake release Instruction label concerning lifting Serial no. from rating label Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 134 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare part lists on page 345. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 135: Inspecting The Axis-1 Mechanical Stop Pin
The axis-1 mechanical stop is located as shown in the figure. xx0600002972 Mechanical stop pin, axis 1 Fixed mechanical stop Required equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 136 If the mechanical stop pin is bent or damaged, it must be replaced. Note The expected life of gearboxes can be reduced after collision with the mechanical stop. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 137: Inspecting The Additional Mechanical Stops
Additional mechanical stops are not provided for axis 2. xx0600002938 Additional stop, axis 1 Attachment screws and washers (2 pcs) Fixed stop Mechanical stop pin, axis 1 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 138 Attachment screw and washer • Document for mechanical stop pin Standard toolkit Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 139 Article number is specified in be replaced. Required equipment on page 138. Correct attachment screws: • Axis 1: M12 x 40, quality 12.9. • Axis 3: M6 x 16 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 140: Inspecting The Damper On Axes 2-5
Damper axes 2-3 3HAC12320-1 Damper axis 5 3HAC024541-001 Standard toolkit 3HAC15571-1 Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 141 If any damage is detected, the damper must be re- Art. no. is specified in Required placed with a new one! equipment on page 140. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 142: Inspecting, Signal Lamp
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 143 • Checking cable connections. • Measuring the voltage in connectors motor axis 3 (=24V). • Checking the cabling. Replace cabling if a fault is detected. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 144: Inspection Of Air Hoses (Foundry Prime)
Pressurize by opening the cut off valve. Spray suspected leak areas with leak detec- tion spray. Note Bubbles indicate a leak. When the leak is localized: correct the leak. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 145: Replacement/Changing Activities
The figure shows the location of the gearboxes. xx0600002977 Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearbox, axis 5 Gearbox, axis 6 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 146 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 147: Changing Oil, Axis-1 Gearbox
Content is defined in section ment Special tools on page 341. Standard toolkit Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 148 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 149 116. on page 145. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 150: Changing Oil, Axis-2 Gearbox
Content is defined in section ment Special tools on page 341. Standard toolkit Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 151 Before entering the robot working area. WARNING Handling gearbox oil involves several safety risks, Gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 152 118. page 145. Note Don´t mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 153: Changing Oil, Axis-3 Gearbox
Special tools on page 341. Oil collecting vessel Capacity: 3,000 ml. Standard toolkit Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 154 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 155 121. on page 145. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 156: Changing Oil, Axis-4 Gearbox
Art. no. for the kit is specified in Required equipment on page 156. Action Note Run the upper arm -45° from the calibration position. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 157 Where to find type of oil and total page 123. amount is detailed in Type and amount of oil in gearboxes on page 145. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 158 3 Maintenance 3.4.5 Changing oil, axis-4 gearbox Continued Action Note Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 159: Changing Oil, Axis-5 Gearbox
Required equipment on page 159. Action Note Move the robot to its calibration position. This puts the oil plug draing in the right position. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 160 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 145. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 161: Changing Oil, Axis-6 Gearbox
Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. The figure shows gearbox axis 6 for IRB 6620 Foundry Plus. xx0600002964 Gearbox axis 6 Oil plug, filling...
Page 162 145. Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 163 3.4.7 Changing oil, axis-6 gearbox Continued Action Note Inspect the oil level. Detailed in the section Inspecting the oil level in axis-6 gearbox on page 127. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 164: Replacing The Smb Battery
The SMB battery (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below. xx0600002982 Attachment screws SMB/BU unit (complete) Velcro strap Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 165 Equipment, etc. Spare part no. Note Battery pack For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part approved equivalent. lists on page 345 Standard toolkit Content is defined in section...
Page 166 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 164. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
Page 167 Detailed in chapter Calibration - section Updating revolution coun- ters on page 307. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 168: Cleaning Activities
General To secure high uptime it is important that the IRB 6620 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works. Different cleaning methods are allowed depending on the type of protection of the IRB 6620.
Page 169 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
Page 170 3 Maintenance 3.5.1 Cleaning the IRB 6620 Continued • Clean the cables if they have a crusty surface, for example from dry release agents. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 171: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 6620, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 172: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 173: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 174 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 175: Mounting Instructions For Sealings
If the sealing is without dust lip, just lubricate the main lip with a thin layer of grease. xx2000000071 A Main lip B Grease C Dust lip Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 176 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 177 Lubricate the o-ring with grease. Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 178: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 179: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 180: Complete Robot
The cable harness for axes 1-2 is run throughout the base and frame as shown in the figure below. xx0600002970 SMB/BU unit Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 181 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 182 Shown in the figure Location of cable harness, axes tion box from the robot by re- 1-2 on page 180. moving its attachment screws. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 183 Remove the metal clamps on Shown in the figure Location of cable harness, axes the frame, securing the cable 1-2 on page 180. harness. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 184 R1.MP and R1.SMB at the con- Shown in the figure Location of cable harness, axes nection plate, base. 1-2 on page 180. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 185 180. ness. Refit the top cover, connection Shown in the figure Location of cable harness, axes box. 1-2 on page 180. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 186 General calibration information is included in section Calibration on page 299. DANGER Make sure all safety require- ments are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 187: Replacement Of Cable Harness, Upper End
Attachment screws, metal clamp lower arm, M6x16 quality 8.8 (2+2 pcs) Metal clamp, armhouse Attachment screws, metal clamp armhouse, M6x16 quality 8.8 (2 pcs) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 188 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 189 Make sure not to lose the washers placed xx0600003024 in the holes of the foundry gasket. • A : Cover, wrist unit xx1400002580 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 190 A : Cable holder • B : Attachment screws M6x16, 8.8 (2 pcs) • C : Attachment screw M4x12, 8- A2F (securing the carrier) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 191 Use caution and pull out the cable harness of the upper arm. Tie the connectors into a bundle, to avoid damaging them during further removal. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 192 Refit cover motor, axis 6. Reconnect the motor cables axis 5 R2.MP5 Shown in the figure Location of cable and R2.FB5. harness on page 187 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 193 A : Cable harness • B : Motor, axis 5 • C : Attachment screws M6x16, 8.8 (2 pcs) • D : Metal clamp Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 194 Make sure the wrist cover gasket and the small gasket fitted in the recess of the wrist cover are undamaged. Replace if damaged. xx1400002579 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 195 Fit the Foundry Plus cover on the adapter ring. xx1400002582 Make sure the gasket on the adapter ring is undamaged. Replace if damaged. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 196 General calibration information is included in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 197: Replacement Of Complete Arm System
Attachment screws base M12x80, quality 12.9 Gleitmo (16 pcs) Required equipment Equipment, etc. Art. no. Note Lifting accessory, robot 3HAC026597-001 Instruction 3HAC026600-002 is en- closed! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 198 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 199 Manually releasing the brakes on page xx0600003125 Run the overhead crane to a position above the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 200 (axes 1-2) on page 180. gearbox. Remove the motor, axis 1. Detailed in section Replacement of motor, axis 1 on page 237. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 201 E : Roundsling (used to transfer the load of the frame) Remove the mechanical stop pin from the frame. xx1200000668 A Mechanical stop pin Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 202 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 203 • A : Lifting tool • B : Roundsling • C : Lifting chain • D : Hoisting block Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 204 Adjust the length of the chains as detailed in enclosed instruction or with a hoisting block. Clean the mounting surfaces with isopropan- Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 205 B Hole for attachment screw. Lubricate the outer surface of the gearbox for easier mating of the gearbox and arm system. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 206 (axes 1-2) on page 180. Refill the gearbox with lubricating oil. Detailed in section Changing oil, axis-1 gearbox on page 147. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 207 General calibration information is included in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 208: Upper And Lower Arm
Location of turning disk The turning disk is located in the front of the wrist housing as shown in the figure below. The figure shows the turning disk on an IRB 6620 Foundry Plus/IRB 6620LX. xx0600003082 Turning disk Wrist unit...
Page 209 208. Remove the turning disk. Foundry Plus: Remove old flange sealant residues and other con- tamination from the contact surfaces. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 210 See section • Changing oil, axis-6 gearbox on page 161 Refit any equipment removed during disas- sembly to the turning disk. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 211 4 Repair 4.4.1 Replacing the turning disk Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 212: Replacement Of Wrist Unit
345. Wrist unit, insulated Spare part lists on page 345. Retrofit set Foundry Plus, Spare part lists wrist on page 345. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 213 Move the robot to a suitable position for removal of the wrist unit. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 214 Action Note Secure the wrist unit with a roundsling in an over- head crane and lift it to its mounting position. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 215 Axis Calibration is described in Calibrating with Axis Calibration method on page 311. General calibration information is included in section Calibration on page 299. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 216 Action Note Refit any equipment previously removed from the wrist unit. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 217: Replacement Of The Upper Arm
Instruction 3HAC026600- 002 is enclosed. Lifting chain Roundsling Guiding pins Always use in pairs. Hoisting block Grease 3HAC042536-001 Used to lubricate o-rings. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 218 The procedure below details how to remove the upper arm. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 219 D : Hoisting block Remove the cable harness, axes 3-6. Detailed in the section Replacement of cable harness, upper end on page 187. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 220 The complete upper arm (incl. gearbox axis 3) weighs 282 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 221 172. Refit the cable harness, axes 3-6. Detailed in section Replacement of cable harness, upper end on page 187. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 222 General calibration information is included in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 223: Replacement Of Lower Arm
Attachment screws, M16x50 quality 12.9 Gleitmo (16 pcs) xx0600003059 Lower arm Hole in lower arm Gearbox, axis 2 Attachment screws, M16x50 quality 12.9 Gleitmo (16 pcs) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 224 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 225 Detailed in the section Replacement of the upper arm on page 217. Secure the lower arm with a roundsling in an overhead crane. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 226 Calib- rating with Axis Calibration method on page 311. General calibration information is in- cluded in section Calibration on page 299. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 227 4 Repair 4.4.4 Replacement of lower arm Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 228: Frame And Base
Serial measurement unit (SMB), RMU 101 Brake release unit (BU), DSQC 1050 Push button guard Cover, push button guard Gasket (Foundry Plus) Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 229 Clean cover from metal residues before open- ing. Metal residues can cause shortage on the boards which can result in hazardous failures. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 230 A: Hexagon nut, M5 • B: Tooth lock washer, 6.4 fzb • C: Hexagon screw, M5x12 quality 8.8 Pull the SMB unit out carefully. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 231 Location of SMB the attachment screws. unit on page 228. Update the revolution counters! Detailed in section Updating revolution counters on page 307. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 232 4 Repair 4.5.1 Replacement of SMB unit Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 233: Replacing The Brake Release Board
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 234 Location of the brake release unit is shown in the figure Location of brake release board on page 233. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 235 Refit the push button guard to the SMB cover. Shown in the figure Location of brake release board on page 233. Refit the cover, push button guard. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 236 Updating revolution counters on page 307. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 237: Motors
The motor axis 1 is located as shown in the figure below. xx0600003037 Motor, axis 1 Motor attachment screws and washers Cable gland Cover Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 238 See references to quired. these procedures in the step-by-step in- structions below. Circuit diagram See chapter Circuit dia- gram on page 347. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 239 Remove the cover for connector access on top of Shown in the figure Location of the motor by unscrewing its four attachment screws. motor on page 237. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 240 238. ring with grease. CAUTION The motor weighs 25 kg! All lifting equipment used must be sized accordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 241 General calibration information is included in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 242: Replacement Of Motor Axis 2
For guiding the motor. Guides are to be used in pairs! Lifting tool, motor ax 3HAC026061-001 Extension bar, 300 3HAC12342-1 mm for bits 1/2" Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 243 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 244 Changing oil, axis-2 gear- box on page 150. Remove the cover on top of the mo- tor by unscrewing its four attach- ment screws. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 245 Remove the motor by gently lifting it straight out and place it on a se- cure surface. Disconnect the brake release voltage. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 246 Location of motor on page 242. Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 247 General calibration information is in- cluded in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 248: Replacement Of Motor, Axis 3
Used to rotate the motor pin- ion when mating it to the gear when brakes are released with 24 VDC power supply. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 249 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 250 The motor axis 3 can now be replaced without securing the armsys- tem in an overhead crane. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 251 Remove the motor by gently lifting Make sure the motor pinion is not damaged! it straight out and disconnect the brake release voltage. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 252 In order to release the brake, connect the 24 VDC Connect to connector R2.MP3 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 253 Cal- ibrating with Axis Calibration meth- od on page 311. General calibration information is included in section Calibration on page 299. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 254 4 Repair 4.6.3 Replacement of motor, axis 3 Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 255: Replacement Of Motor, Axis 4
24 VDC, max. 1,5 A For releasing the brakes. Standard toolkit Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 256 The procedure below details how to remove the motor, axis 4. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 257 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 258 Detailed in the section Performing a leak- been drained. down test on page 172. Refill the gearbox with oil if drained. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 259 General calibration information is included in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 260: Replacement Of Motor, Axis 5 , Irb 6620/6620Lx
4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Location of motor The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below.
Page 261 4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Continued Equipment, etc. Art. no. Note Removal tool, motor M10x 3HAC14972-1 Always use the removal tools in pairs! Extension bar 300 mm for 3HAC12342-1 bits 1/2" Guide pins M8 x 100 3HAC15520-1 For guiding the motor.
Page 262 4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Continued Removal, motor, axis 5 The procedure below details how to remove motor, axis 5. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.
Page 263 4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Continued Action Note If required, press the motor out of position by fit- Art. no. is specified in Required ting removal tool, motor, M10 to the motor attach- equipment on page 260.
Page 264 4 Repair 4.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX Continued Action Note Foundry Plus Make sure that the gasket is undamaged. Also the small gasket fitted in the cover recess. Replace if damaged. xx1400002579 Foundry Plus Make sure the washers are fitted in the gasket holes.
Page 265 Must be replaced when reas- sembling motor! Gasket 3HAC048560-001 Must be replaced when repla- cing motor Gasket, cover 3HAC033489-001 Must be replaced when opening cover. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 266 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 267 Connect the 24 VDC power supply to release the Connect to connector R3.MP6 brakes. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 268 In order to release the brake, connect the 24 Connect to connector R3.MP6 VDC power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 269 Calib- rating with Axis Calibration method on page 311. General calibration information is in- cluded in section Calibration on page 299. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 270 • E: Gasket Continue to remove the motor unit, according to step 6 and forwards in Removal, motor on page 267. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 271 Apply Loctite 574 flange sealant on the contact surface. xx1400000992 Apply grease on the o-ring on the motor. Continue to refit the new motor according to section, Refitting, motor on page 268. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 272: Gearboxes
Includes: on page 345. • gearbox • o-ring O-ring 3HAB3772-93 Replace only when dam- aged. 380.6x3.53 O-ring (3 pcs) 3HAB3772-97 23x3.6 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 273 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 274 Art. no. is specified in Required equipment allow fitting the support, base and gear axis on page 272. 1 on each side of the base. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 275 1, this should axis 1 is detailed in section Removal on be done first. page 274. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 276 Lift the gearbox on to the guide pins and lower it carefully to its mounting position. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 277 CAUTION The complete arm system weighs 590 kg! All lifting equipment used must be sized ac- cordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 278 • A : Lifting tool • B : Roundsling • C : Lifting sling • D : Hoisting block Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 279 • A: Serrated lock washer • B: Gearbox, axis 1 • C: Attachment screw, M12x80 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 280 General calibration information is in- cluded in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 281: Replacement Gearbox Axis 2
3HAC020999-001 Used to turn the gear in correct position. Standard toolkit Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 282 The procedure below details how to remove gearbox axis 2. Action Note Decide which calibration routine to use, and take actions accord- ingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 283 D : Hoisting block Drain the oil from gearbox axis 2. Detailed in the section Changing oil, axis-2 gearbox on page 150. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 284 Fit two guide pins in the holes, parallel to each other. CAUTION The gearbox weighs 98 kg! All lift- ing equipment used must be sized accordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 285 Note Make sure the o-ring is fitted to the gearbox. Lightly lubricate it with grease. xx0600003128 • A : O-ring 3HAB3772-91 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 286 The upper and lower arms (in- cl. gearboxes axes 2 and 3) weighs 455 kg. All lifting equipment used must be sized accordingly! Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 287 General calibration information is included in section Calibration on page 299. DANGER Make sure all safety require- ments are met when perform- ing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 288: Replacement Of Gearbox Axis 3
Instructions 3HAC 026600-002 is enclosed. Lifting tool 3HAC025214-001 For lifting gearbox. Standard toolkit Content is defined in section Standard tools on page 340. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 289 The procedure below details how to remove gearbox axis 3. Action Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 291 General calibration information is in- cluded in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 292: Replacement Of Gearbox, Axis 6
Attachment screws, gearbox Oil plug, draining Oil plug, filling Turning disk Attachment screws, turning disk xx0200000219 Gearbox, axis 6 (IRB 6620 Foundry Plus) Attachment screws and washers Oil plug, draining Oil plug, filling Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W ©...
Page 293 These procedures include refer- may be required. See refer- ences to the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 294 209. Remove the gearbox by unscrewing its attach- Shown in the figure Location of gearbox ment screws. on page 292. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 295 • hydraulic pressure supply to the ro- • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 296 Screw joints on page 336 before fitting. Refit the turning disc. Detailed in the section Refitting, turning disk on page 210. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 297 General calibration information is included in section Calibration on page 299. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 298 This page is intentionally left blank...
Page 299: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 300: Calibration Methods
To regain 100% Absolute accuracy perform- ance, the robot must be recalibrated for abso- lute accuracy after repair or maintenance that affects the mechanical structure. xx0400001197 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 301 Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 6620 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
Page 302 Levelmeter calibration - alternative method Levelmeter calibration is referred to as the alternative method for calibration of ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.
Page 303: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 304: Synchronization Marks And Axis Movement Directions
5.2.1 Synchronization marks and synchronization position for axes Introduction This section shows the position of the synchronization marks and the synchronization position for each axis. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 305 Synchronization mark, axis 1 Synchronization mark, axis 2 Synchronization mark, axis 3 Synchronization mark, axis 4 Synchronization mark, axis 5 Synchronization mark, axis 6 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 306: Calibration Movement Directions For All Axes
Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 307: Updating Revolution Counters
4 and 6 of the following mentioned manipulators are positioned correctly. The axes can be calibrated at the wrong turn, resulting in an incorrect manipulator calibration. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 308 Step 2 - Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 309 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 310 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 328. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 311: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 312 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 313 Axis must be put in position 0 degrees. How to calibrate a suspended robot The IRB 6620 is calibrated floor standing in factory, prior to shipping. To calibrate a suspended robot, reference calibration must be used. Reference values for a suspended robot must be created with the robot mounted at its working position, not standing on a floor.
Page 314: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 315 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 316: Installation Locations For The Calibration Tools
A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows. xx1600000001 xx1600000011 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 317 Replace damaged parts with new. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 318: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 319 This is shown in the Calibration Method Overview ration. window on the FlexPendant. Calibrating with Wrist Optimiza- tion method on page 326. xx2000000509 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 320 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 321 To be able to run Axis Calibration, SafeMove needs to be unsynchronized. The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 322 If the standard calibration data for axes 4, 5 or 6 Calibrating with Wrist Optimiz- should be updated with wrist optimization, run the ation method on page 326. calibration routine Wrist Optimization. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 323: Reference Calibration
(step 5, see Brief introduction to Reference Calibration on page 323). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 324 10 Check again against the verification position. 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 325: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 326: Calibrating With Wrist Optimization Method
WARNING Robot moves automatically when pressing Calibrate. 6 Wrist optimization is finished. 7 Redefine / verify TCP for all tools. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 327: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 328: Checking The Synchronization Position
If they do not, up- ization position for axes on page 304 date the revolution counters. Updating revolution counters on page 307. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 329: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 330 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 331: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 332 This page is intentionally left blank...
Page 333: Reference Information
Degrees of protection provided by enclosures (IP code) Only robots with protection Clean Room. Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots. Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 334 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 335: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 336: Screw Joints
7.3 Screw joints 7.3 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 337 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 338 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 339: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 340: Standard Tools
To be shortened to 12 mm Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 341: Special Tools
Description Art. no. Extension 300mm for bits 1/2" 3HAC12342-1 Guide pins M8 x 100 3HAC15520-1 Guide pins M8 x 150 3HAC15520-2 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 342 Lifting eye (used together with lifting tool 3HAC025333-005 3HAC 15556-1) Lifting tool, gearbox 3HAC025214-001 Guide pins, M12x130 3HAC022637-001 Guide pins, M16x Lifting eye, M16 3HAC14457-1 Lifting eye, M20 Crank Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 343: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 344 This page is intentionally left blank...
Page 345: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 346 This page is intentionally left blank...
Page 347: Circuit Diagram
Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 348 9 Circuit diagram 9.1 Circuit diagrams Continued Product Article numbers for circuit diagrams Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001...
Page 349: Index
325 grease, 34 calibration position disposal, 329 jogging to, 328 guide pins, base plate, 77 scales, 304 calibration scales, 304 CalibWare, 300 hanging Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 350 1, 102 motor axis 3, replacement, 248 working range axis 3, 104 motor axis 4, replacement, 255 revolution counters motor axis 5, replacement, 260 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 351 EN IEC, 333 overview of method, 326 EN ISO, 333 start of robot in cold environments, 110 steel zero position disposal, 329 checking, 328 storage conditions, 54 Product manual - IRB 6620 3HAC027151-001 Revision: W © Copyright 2006-2020 ABB. All rights reserved.
Page 354 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2006-2020 ABB. All rights reserved. Specifications subject to change without notice.

ABB IRB 6620 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Reference Information

8 Spare Part Lists

9 Circuit Diagram

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