ABB Robotics IRB 6790 User manual

ROBOTICS
Product manual
IRB 6790

Trace back information:
Workspace 20A version a8
Checked in 2020-03-09
Skribenta version 5.3.033

Product manual
IRB 6790 - 235/2.65
IRB 6790 - 205/2.80
IRC5
Document ID: 3HAC063331-001
Revision: B
© Copyright 2019 - 2020 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2019 - 2020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation ....................................................................................................................
14How to read the product manual ......................................................................................................
15Important information about robots with protection type Foundry Prime ......................................
171 Safety
171.1 Safety information .............................................................................................
171.1.1 Limitation of liability .................................................................................
181.1.2 Requirements on personnel ......................................................................
191.2 Safety signals and symbols .................................................................................
191.2.1 Safety signals in the manual ......................................................................
211.2.2 Safety symbols on manipulator labels .........................................................
271.3 Robot stopping functions ....................................................................................
281.4 Installation and commissioning ............................................................................
311.5 Maintenance and repair ......................................................................................
311.5.1 Maintenance and repair ............................................................................
341.5.2 Emergency release of the robot axes ..........................................................
351.5.3 Brake testing ..........................................................................................
361.6 Troubleshooting ................................................................................................
371.7 Decommissioning ..............................................................................................
392 Installation and commissioning
392.1 Introduction to installation and commissioning .......................................................
402.2 Unpacking .......................................................................................................
402.2.1 Pre-installation procedure .........................................................................
442.2.2 Working range ........................................................................................
472.2.3 Risk of tipping/stability .............................................................................
482.2.4 Main dimensions .....................................................................................
492.2.5 The unit is sensitive to ESD .......................................................................
502.3 On-site transportation ........................................................................................
502.3.1 Robot transportation precautions ...............................................................
542.3.2 Securing the robot with a transport support .................................................
552.4 On-site installation ............................................................................................
552.4.1 Brief installation procedure .......................................................................
562.4.2 Lifting the base plate ................................................................................
572.4.3 Securing the base plate ............................................................................
602.4.4 Lifting the robot ......................................................................................
602.4.4.1 Lifting the robot with fork lift ..........................................................
612.4.4.2 Lifting the robot with roundslings ....................................................
652.4.5 Orienting and securing the robot ................................................................
682.4.6 Installation requirements for Foundry Prime robots .......................................
772.4.6.1 Shut-down periods .......................................................................
782.4.7 Manually releasing the brakes ...................................................................
802.4.8 Loads fitted to the robot, stopping time and braking distances .........................
812.4.9 Fitting equipment to the robot ...................................................................
882.5 On-site storage .................................................................................................
882.5.1 Increase the lifetime of the robot ................................................................
892.6 Restricting the working range ..............................................................................
892.6.1 Axes with restricted working range .............................................................
902.6.2 Mechanically restricting the working range of axis 1 ......................................
922.7 Electrical connections ........................................................................................
922.7.1 Robot cabling and connection points ..........................................................
942.8 Start of robot in cold environments ......................................................................
953 Maintenance
953.1 Introduction ......................................................................................................
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963.2 Maintenance schedule and expected component life ...............................................
963.2.1 Specification of maintenance intervals ........................................................
973.2.2 Maintenance schedule .............................................................................
993.2.3 Expected component life .........................................................................
1003.3 Inspection activities ...........................................................................................
1003.3.1 Inspecting the oil level in axis-1 gearbox .....................................................
1033.3.2 Inspecting the oil level in axis-2 gearbox .....................................................
1053.3.3 Inspecting the oil level in axis-3 gearbox .....................................................
1073.3.4 Inspecting the oil level in axis-4 gearbox .....................................................
1093.3.5 Inspecting the oil level in axis-5 gearbox .....................................................
1113.3.6 Inspecting the oil level in axis-6 gearbox .....................................................
1143.3.7 Inspecting the balancing device ................................................................
1183.3.8 Inspecting the cable harness ....................................................................
1203.3.9 Inspecting the axis-1 mechanical stop pin ...................................................
1223.3.10 Inspecting the additional mechanical stops .................................................
1243.3.11 Inspecting the fork lift accessory ................................................................
1263.3.12 Inspecting the dampers ...........................................................................
1283.3.13 Inspecting the leak flow (overpressure unit) in the system ..............................
1303.4 Analyzing activities ............................................................................................
1303.4.1 Analyzing the water content in gearbox oil ...................................................
1313.5 Replacement/changing activities ..........................................................................
1313.5.1 Type of lubrication in gearboxes ................................................................
1323.5.2 Changing oil, axis-1 gearbox .....................................................................
1373.5.3 Changing oil, axis-2 gearbox .....................................................................
1423.5.4 Changing oil, axis-3 gearbox .....................................................................
1463.5.5 Changing oil, axis-4 gearbox .....................................................................
1503.5.6 Changing oil, axis-5 gearbox .....................................................................
1543.5.7 Changing oil, axis-6 gearbox .....................................................................
1583.5.8 Replacing the SMB battery .......................................................................
1613.6 Cleaning activities .............................................................................................
1613.6.1 Cleaning the IRB 6790 .............................................................................
1654 Repair
1654.1 Introduction ......................................................................................................
1664.2 General procedures ...........................................................................................
1664.2.1 Performing a leak-down test ......................................................................
1674.2.2 Mounting instructions for bearings .............................................................
1694.2.3 Mounting instructions for sealings ..............................................................
1724.2.4 Dismantle and mounting tool, 3HAC028920-001 ............................................
1734.2.5 Painting damaged nickel coated surfaces with touch up paint .........................
1744.2.6 The brake release buttons may be jammed after service work .........................
1754.3 Lifting associated procedures ..............................................................................
1754.3.1 Attaching lifting accessories to complete arm system ....................................
1794.3.2 Attaching lifting accessories to an un-separated lower and upper arm ...............
1844.3.3 Attaching lifting accessories to the upper arm ...............................................
1874.4 Complete robot .................................................................................................
1874.4.1 Removing the cable harness ....................................................................
2094.4.2 Refitting the cable harness .......................................................................
2404.4.3 Replacing the SMB .................................................................................
2474.4.4 Replacing the brake release unit ...............................................................
2534.5 Upper and lower arms ........................................................................................
2534.5.1 Replacing the upper arm ..........................................................................
2894.5.2 Replacing the wrist .................................................................................
3114.5.3 Replacing the turning disc ........................................................................
3164.5.4 Replacing the lower arm ..........................................................................
3674.6 Frame and base ................................................................................................
3674.6.1 Replacing spherical roller bearing, link ear ...................................................
3824.6.2 Replacing the balancing device .................................................................
3994.6.3 Replacing the rear bearings on the balancing device .....................................
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4114.6.4 Unloading the balancing device .................................................................
4154.6.5 Restoring the balancing device .................................................................
4184.6.6 Replacing the stop pin .............................................................................
4224.7 Motors ............................................................................................................
4224.7.1 Replacing the axis-1 motor .......................................................................
4344.7.2 Replacing the axis-2 motor .......................................................................
4474.7.3 Replacing the axis-3 motor .......................................................................
4604.7.4 Replacing the axis-4 motor .......................................................................
4724.7.5 Replacing the axis-5 motor .......................................................................
4874.7.6 Replacing the axis-6 motor .......................................................................
5014.8 Gearboxes .......................................................................................................
5014.8.1 Replacing the axis-1 gearbox ....................................................................
5424.8.2 Replacing the axis-2 gearbox ....................................................................
5764.8.3 Replacing the axis-3 gearbox ....................................................................
6024.8.4 Replacing the axis-6 gearbox ....................................................................
6135 Calibration
6135.1 Introduction to calibration ...................................................................................
6135.1.1 Introduction and calibration terminology ......................................................
6145.1.2 Calibration methods .................................................................................
6165.1.3 When to calibrate ...................................................................................
6175.2 Synchronization marks and axis movement directions .............................................
6175.2.1 Synchronization marks and synchronization position for axes .........................
6185.2.2 Calibration movement directions for all axes ................................................
6195.3 Updating revolution counters ...............................................................................
6235.4 Calibrating with Axis Calibration method ...............................................................
6235.4.1 Description of Axis Calibration ..................................................................
6265.4.2 Calibration tools for Axis Calibration ...........................................................
6285.4.3 Installation locations for the calibration tools ...............................................
6295.4.4 Axis Calibration - Running the calibration procedure ......................................
6345.4.5 Reference calibration ...............................................................................
6365.5 Verifying the calibration ......................................................................................
6375.6 Checking the synchronization position ..................................................................
6396 Decommissioning
6396.1 Environmental information ..................................................................................
6416.2 Scrapping of robot .............................................................................................
6426.3 Decommissioning of balancing device ...................................................................
6457 Reference information
6457.1 Introduction ......................................................................................................
6467.2 Applicable standards .........................................................................................
6477.3 Unit conversion .................................................................................................
6487.4 Screw joints ....................................................................................................
6517.5 Weight specifications .........................................................................................
6527.6 Standard toolkit ................................................................................................
6537.7 Special tools ....................................................................................................
6577.8 Lifting accessories and lifting instructions ..............................................................
6598 Spare parts
6598.1 Spare part lists and illustrations ...........................................................................
6619 Circuit diagrams
6619.1 Circuit diagrams ................................................................................................
663Index
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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope
The manual covers covers all variants and designs of the IRB 6790 . Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Safety, service
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Maintenance
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
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Overview of this manual

ContentsChapter
Calibration procedures and general information about calibration.Calibration
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards, etc.
Reference information
Reference to the spare part list for the robot.Spare parts and exploded
views
Reference to the circuit diagram for the robot.Circuit diagram
References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC064429-001Product manual, spare parts - IRB 6790
3HAC064168-001Product specification - IRB 6790
3HAC048484-002Directions for use - Fork lift accessory for IRB 6700
3HAC043446-005Circuit diagram - IRB 6700 / IRB 6790
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore con-
troller i
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC021313-001IRC5 with main computer DSQC 639.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition.A
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Overview of this manual
Continued

DescriptionRevision
Published in release 20A. The following updates are made in this revision:
• Corrected article number for guide pin M12x200 and removal tool
M12. Deleted guide pin M12x250 from special tool list.
• Self-threading screws removed from motor covers.
•Removed incorrect information about upper arm connection plate.
• Updated information about wrist cover gasket.
• Added note to operating environment information regarding pH
value in washing detergents.
• Added images to section for transportation of a robot that has a
tool mounted.
• Added image of hole configuration of the base.
• Added overpressure diagram to section Installation requirements
for Foundry Prime robots on page 68.
• Added information about action if the system alerts for too high
leakage.
• Added information about working range restrictions.
• Updated information about cable clamp attachment inside the
upper arm tube.
• Updated information about requirement of the cable protection
on axis 1.
• Updated article numbers of motor cover o-rings and connection
box o-rings.
• Added information about screws at the balancing device front link
ear shaft insert.
• Replaced article number and name of grease, previously
3HAB3537-1.
•Clarified and added information in mounting instructions for rotat-
ing sealings, see Mounting instructions for sealings on page 169.
•Clarified text about position of robot and added table with depend-
encies between axes during Axis Calibration.
B
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Continued

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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
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Product documentation

Operating manuals
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.
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Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.
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How to read the product manual

Important information about robots with protection type
Foundry Prime
Introduction
Foundry Prime robots are specially designed to work in harsh environments. Misuse
of the robots or poor installation, cleaning, maintenance and repair can be harmful
for the functioning of the robot.
Warranty claims
Warranty claims for defect products due to misuse or failure to fulfil operational
and maintenance requirements will not be approved.
Pressurized components
Motors, balancing device and the serial measurement board cavity shall be
pressurized on Foundry Prime robots during operation and shut down. The
overpressure can be dropped when atmospheric humidity has reached the same
level as the surrounding environment.
For more information, see Pressurized system on page 73.
Cleaning
Special procedures are needed when cleaning the Foundry Prime robot. See section
Cleaning the IRB 6790 on page 161.
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Important information about robots with protection type Foundry Prime

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1 Safety
1.1 Safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment
ABB supplies original spare parts and equipment which have been tested and
approved. 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.
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1 Safety
1.1.1 Limitation of liability

1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
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.
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1 Safety
1.1.2 Requirements on personnel

1.2 Safety signals and symbols
1.2.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
For more information, see standard ISO 13849.
SignificanceDesignationSymbol
Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
DANGER
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in serious
injury.
WARNING
Signal word used to indicate a potentially hazardous
situation related to electrical hazards which, if not
avoided, could result in serious injury.
ELECTRICAL
SHOCK
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in slight
injury.
CAUTION
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in severe
damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
Signal word used to indicate important facts and
conditions.
NOTE
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1 Safety
1.2.1 Safety signals in the manual

SignificanceDesignationSymbol
Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.
TIP
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1 Safety
1.2.1 Safety signals in the manual
Continued