ABB IRB 6600 - 175/2.55 User manual


Product Manual
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A

Product Specification
3HAC 14064-1/M2000/Rev 2
IRB 6600 - 175/2.55
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6650 - 125/3.2
IRB 6650 - 200/2.75

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation
Technology Products AB, Robotics’s written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
© Copyright 2001 ABB. All rights reserved.
Article number: 3HAC 14064-1
Issue: M2000/Rev. 2
ABB Automation Technology Products AB
Robotics
SE-721 68 Västerås
Sweden

Product Specification IRB 6600
CONTENTS Page
Product Specification IRB 6600 M2000 1
1 Description....................................................................................................................... 3
1.1 Structure..................................................................................................................3
Different robot versions ......................................................................................... 4
Definition of version designation........................................................................... 4
1.2 Safety/Standards..................................................................................................... 6
1.3 Installation.............................................................................................................. 10
External Mains Transformer .................................................................................. 10
Operating requirements.......................................................................................... 10
Mounting the manipulator...................................................................................... 10
1.4 Load diagrams ........................................................................................................ 13
Maximum load and moment of inertia for full and limited axis 5
(centre line down) movement......................................................................... 24
Mounting equipment.............................................................................................. 25
Holes for mounting extra equipment ..................................................................... 26
1.5 Maintenance and Troubleshooting ......................................................................... 30
1.6 Robot Motion.......................................................................................................... 31
Performance according to ISO 9283...................................................................... 34
Velocity .................................................................................................................. 34
1.7 Cooling fan for axis 1-3 motor (option 113-115) ................................................... 34
1.8 SpotPack and DressPack ........................................................................................ 35
Description of DressPack....................................................................................... 37
Description of Water and Air unit.......................................................................... 39
Description of Power Unit ..................................................................................... 40
1.9 Description of Variants and Options for SpotPack................................................. 41
1.10 Examples of SpotPacks ........................................................................................ 59
1.11 Servo Gun (option) ............................................................................................... 62
1.12 Track Motion ........................................................................................................ 68
2 Specification of Variants and Options........................................................................... 69
3 Accessories....................................................................................................................... 79
4 Index................................................................................................................................. 81

Product Specification IRB 6600
2 Product Specification IRB 6600 M2000

Description
Product Specification IRB 6600 M2000 3
1 Description
1.1 Structure
A new world of possibilities opens up with ABB’s IRB 6600 robot family. It comes in
five versions, 175kg /2.55m, 225kg /2.55 m, 175kg /2.8m, 125kg/3.2m, and
200kg/2.75m handling capacities.
TheIRB6600 isidealfor process applications,regardlessofindustry. Typicalareas can
be spotwelding, material handling and machine tending.
We haveadded a range of software products - allfalling under the umbrella designation
of Active Safety - to protect not only personnel in the unlikely event of an accident, but
also robot tools, peripheral equipment and the robot itself.
The robot is equipped with the operating system BaseWare OS. BaseWare OS controls
every aspect of the robot, like motion control, development and execution of
application programs, communication etc. See Product Specification S4Cplus.
For additional functionality, the robot can be equipped with optional software for
application support - for example spot welding, communication features - network
communication - and advanced functions such as multi-tasking, sensor control, etc.
For a complete description on optional software, see the Product Specification
RobotWare Options.
Figure 1 The IRB 6600 manipulators have 6 axes.
Axis 6
Axis 3
Axis 4
Axis 5
Axis 1
Axis 2

Description
4 Product Specification IRB 6600 M2000
Different robot versions
The IRB 6600 is available in five versions. The following different robot types are
available:
Standard:
IRB 6600 - 175 kg / 2.55 m
IRB 6600 - 225 kg / 2.55 m
IRB 6600 - 175 kg / 2.8 m
IRB 6650 - 125 kg / 3.2 m
IRB 6650 - 200 kg / 2.75 m
Definition of version designation
IRB 6600 Mounting - Handling capacity / Reach
Manipulator weight IRB 6600-175/2,55 1700 kg
IRB 6600-225/2,55 1700 kg
IRB 6600-175/2,8 1700 kg
IRB 6650-125/3.2 1725 kg
IRB 6650-200/2.75 1700 kg
Airborne noise level:
The sound pressure level outside < 73 dB (A) Leq (acc. to
the working space Machinery directive 98/37/EEC)
Power consumption at max load:
ISO Cube: 2.6 kW
Normal robot movements: 3.8 kW
Prefix Description
Mounting - Floor-mounted manipulator
Handling capacity yyy Indicates the maximum handling capacity (kg)
Reach x.x Indicates the maximum reach at wrist centre (m)

Description
Product Specification IRB 6600 M2000 5
Figure 2 View of the manipulator from the side and above (dimensions in mm).
Allow 200 mm behind the manipulator foot for cables.
6600-400/2.55
1142 IRB 6600-2,55
1392 IRB 6600-2,8
R 580
R 690 with fork lift
1592 IRB 6650-3.2
; IRB 6650-2.75
2445 IRB 6650
2240 IRB 6600
IRB 6600
1280 IRB 6650

Description
6 Product Specification IRB 6600 M2000
1.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1 Safety of machinery, terminology
EN 292-2 Safety of machinery, technical specifications
EN 954-1 Safety of machinery, safety related parts of control
systems
EN 60204 Electrical equipment of industrial machines
IEC 204-1 Electrical equipment of industrial machines
ISO 10218, EN 775 Manipulating industrial robots, safety
ANSI/RIA 15.06/1999 Industrial robots, safety requirements
ISO 9787 Manipulating industrial robots, coordinate systems
and motions
IEC 529 Degrees of protection provided by enclosures
EN 50081-2 EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
The Service Information System (SIS)
The service information system gathers information about the robot’s usage and by that
determines how hard the robot has been used. The usage is characterised by the speed,
the rotation angles and the load of every axis.
With this data collection, the service interval of every individual robot of this generation
can be predicted, optimising and planning ahead service activities. The collection data is
available via the teach pendant or the network link to the robot.
The Process Robot Generation is designed with absolute safety in mind. It is dedicated
to actively or passively avoid collisions and offers the highest level of safety to the
operators and the machines as well as the surrounding and attached equipment. These
features are presented in the active and passive safety system.
The Active Safety System
The active safety system includes those software features that maintain the accuracy of
the robot’s path and those that actively avoid collisions which can occur if the robot
leaves the programmed path accidentally or if an obstacle is put into the robot’s path.
The Active Brake System (ABS)
All robots run with an active brake system that supports the robots to maintain the
programmed path even in an emergency situation.

Description
Product Specification IRB 6600 M2000 7
The ABS is active during all stop modes, braking the robot to a stop with the power of
the servo drive system along the programmed path. After a specific time the mechanical
brakes are activated ensuring a safe stop even in case of a failure of the drive system or
a power interruption.
The maximal applicable torque on the most loaded axis determines the stopping
distance.
The stopping process is in accordance with a class 1 stop.
While programming the robot in manual mode a class 0 stop, with mechanical brakes
only, applies.
The Self Tuning Performance (STP)
The Process Robot Generation is designed to run at different load configurations, many
of which occur within the same program and cycle.
The robot’s installed electrical power can thus be exploited to lift heavy loads, create a
high axis force or accelerate quickly without changing the configuration of the robot.
Consequently the robot can run in a “power mode”or a “speed mode”which can be
measured in the respective cycle time of one and the same program but with different
tool loads. This feature is based on QuickMoveTM.
The respective change in cycle time can be measured by running the robot in NoMotion-
Execution with different loads or with simulation tools like RobotStudio.
The Electronically Stabilised Path (ESP)
The load and inertia of the tool have a significant effect on the path performance of a
robot. The Process Robot Generation is equipped with a system to electronically
stabilise the robot’s path in order to achieve the best path performance.
This has an influence while accelerating and braking and consequently stabilises the
path during allmotion operations witha compromise of thebestcycletime. Thisfeature
is secured through TrueMoveTM.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Restricting the working space
The movement of each axis can be restricted using software limits.
As options there are safeguarded space stops for connection of position switches to
restrict the working space for the axes 1-3.
Axes 1-3 can also be restricted by means of mechanical stops.
Collision detection (option)
In case an unexpected mechanical disturbance occurs, like a collision, electrode stick-
ing, etc., the robot will detect the collision, stop on the path and slightly back off from
its stop position, releasing tension in the tool.
The Passive Safety System
The Process Robot Generation has a dedicated passive safety system that by hardware
construction and dedicated solutions is designed to avoid collisions with surrounding
equipment. It integrates the robot system into the surrounding equipment safely.
Compact robot arm design
The shape of the lower and upper arm system is compact, avoiding interference into the
working envelope of the robot.

Description
8 Product Specification IRB 6600 M2000
The lower arm is shaped inward, giving more space under the upper arm to re-orientate
large parts and leaving more working space while reaching over equipment in front of
the robot.
The rear side of the upper arm is compact, with no components projecting over the edge
of the robot base even when the robot is moved into the home position.
Moveable mechanical limitation of main axes (option)
All main axes can be equipped with moveable mechanical stops, limiting the working
range of every axis individually. The mechanical stops are designed to withstand a
collision even under full load.
Position switches on main axes (option)
All main axes can be equipped with position switches. The double circuitry to the cam
switches is designed to offer personal safety according to the respective standards.
The Internal Safety Concept
The internal safety concept of the Process Robot Generation is based on a two-channel
circuit that is monitored continuously. If any component fails, the electrical power
supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery -
safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movementsstop when either the enabling device ispushed fully in, or when
it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robot’s safety chain
circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety
equipment, such as safety gates and light curtains. This allows the robot’s safety
functions to be activated both by peripheral equipment and by the robot itself.

Description
Product Specification IRB 6600 M2000 9
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors is shut off.
Hold-to-run control
“Hold-to-run”meansthatyoumustdepressthestartbuttoninordertomovetherobot.When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp (option)
As an option, the robot can be equipped with a safety lamp mounted on the manipula-
tor. This is activated when the motors are in the MOTORS ON state.

Description
10 Product Specification IRB 6600 M2000
1.3 Installation
All versions of IRB 6600 are designed for floor mounting. Depending on the robot
version, an end effector with max. weight of 175 to 225 kg including payload, can be
mounted on the mounting flange (axis 6). See Load diagram for IRB 6600 generation
robots on page 14, page 16, page 18, page 20 and page 22.
Extra loads (valve packages, transformers) can be mounted on the upper arm with a
maximum weight of 50 kg. On all versions an extra load of 500 kg can also be mounted
on the frame of axis 1. Holes for mounting extra equipment on page 26.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axes 1-3 for position indication of the manipulator.
External Mains Transformer
The robot system requires a 400 - 475 VAC power supply. Therefore an external
transformer will be included when a mains voltage other than 400-475V is selected.
Operating requirements
Protection standards
Standard and Foundry Manipulator IP67
Cleanroom standards
Cleanroom class 100 for manipulator according to:
• DIN EN ISO 14644: Cleanrooms and associated controlled environments
• US Federal Standard 209 e -Air-clean-classes
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation +5oC (41oF) to +50oC (122oF)
For the controller: standard +45oC (113oF)
option +52oC (126oF)
Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)
for short periods (not exceeding 24 hours) up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation Max. 95% at constant temperature
Mounting the manipulator
Maximum load in relation to the base coordinate system.
Endurance load Max. load at
in operation emergency stop
Force xy ±10.1 kN ±20.7 kN
Force z 18.0 ±13.8 kN 18.0 ±22.4 kN
Torque xy ±27.6 kNm ±50.6 kNm
Torque z ±7.4 kNm ±14.4 kNm

Description
Product Specification IRB 6600 M2000 11
Figure 3 Hole configuration (dimensions in mm).
88 ± 0.3
Recommended screws for fastening
M24 x 120 8.8 with 4 mm flat washer
Torque value 775 Nm
the manipulator to a base plate:

Description
12 Product Specification IRB 6600 M2000
Figure 4 Option Base plate (dimensions in mm).
1 A
A
A
B
B
CC
D
1.5
0.1
A
A - A
50
10
o
15
o
37,5
o
B - B C - C
D
522
5
Two guiding pins required, dimensions see Figure 5
325

Description
Product Specification IRB 6600 M2000 13
Figure 5 Guide sleeve (dimensions in mm)
1.4 Load diagrams
The load diagrams include a nominal payload inertia, J0of 15 kgm2, and an extra load of 50 kg
at the upper arm housing, see Figure 6.
At different arm load, payload and moment of inertia, the load diagram will be changed.
For an accurate load diagram, please use the calculation program, ABBLoad for 6600 on:
•inside.abb.com/atrm, click on Products --> Robots --> IRB 6600
or
•http://www.abb.com/roboticspartner, click on Product range --> Robots --> IRB 6600.
Figure 6 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).
Protected from corrosion
400
200
Centre of gravity 50 kg

Description
14 Product Specification IRB 6600 M2000
Load diagram for IRB 6600-175/2.55
Figure 7 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,00 0,10 0,20 0,30 0,40 0,50
L-distance (m)
Z-distance (m)
185 kg
180 kg
175 kg
150 kg
135 kg
120 kg
100 kg
80 kg
0,10
200 mm

Description
Product Specification IRB 6600 M2000 15
Load diagram for IRB 6600-175/2.55 “Vertical Wrist” (±10o)
Figure 8 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at “Vertical Wrist” (±10o), J0=15 kgm2.
For wrist down (0odeviation from the vertical line).
Max load = 215 kg, Zmax = 0,310m and Lmax = 0,133m
IRB 6600 - 175/2.55 Armload: 50kg
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
0,00,20,40,60,81,01,21,4
Load diagram "Vertical Wrist" (±10°)
150 kg
210 kg
100 kg
200 mm
0,20
0,40
0,20 0,40
0,60
0,60 0,80
0,80
1,00
1,00
1,20
1,20
1,40
1,40
L-distance (m)
Z-distance (m)
1,00
0,60
Pay
load
10o10o
Z
“Vertical wrist”
L
75 kg
190 kg

Description
16 Product Specification IRB 6600 M2000
Load diagram for IRB 6600-225/2.55
Figure 9 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
0,00 0,10 0,20 0,30 0,40 0,50 0,60
L-distance (m)
Z-distance (m)
175 kg
150 kg
120 kg
100 kg
200 kg
215 kg
225 kg
230 kg
220 kg
0,10
200 mm
0,20