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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10 Product manual - IRB 6790
3HAC063331-001 Revision: B
© Copyright 2019 - 2020 ABB. All rights reserved.
Overview of this manual
Continued