ABB IRB 6620 User manual

ROBOTICS
Product manual
IRB 6620

Trace back information:
Workspace 20B version a14
Checked in 2020-05-29
Skribenta version 5.3.033

Product manual
IRB 6620 - 150/2.2
IRC5
Document ID: 3HAC027151-001
Revision: W
© Copyright 2006-2020 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, damage 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 2006-2020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
15Product documentation ....................................................................................................................
17How to read the product manual ......................................................................................................
191 Safety
191.1 Safety information .............................................................................................
191.1.1 Limitation of liability .................................................................................
201.1.2 Requirements on personnel ......................................................................
211.2 Safety signals and symbols .................................................................................
211.2.1 Safety signals in the manual ......................................................................
231.2.2 Safety symbols on manipulator labels .........................................................
291.3 Robot stopping functions ....................................................................................
301.4 Installation and commissioning ............................................................................
331.5 Operation ........................................................................................................
331.5.1 Unexpected movement of robot arm ...........................................................
341.6 Maintenance and repair ......................................................................................
341.6.1 Maintenance and repair ............................................................................
371.6.2 Emergency release of the robot axes ..........................................................
381.6.3 Brake testing ..........................................................................................
391.7 Troubleshooting ................................................................................................
401.8 Decommissioning ..............................................................................................
412 Installation and commissioning
412.1 Introduction to installation and commissioning .......................................................
422.2 Robot transportation precautions .........................................................................
482.3 Securing the robot with a transport support ...........................................................
512.4 Unpacking .......................................................................................................
512.4.1 Pre-installation procedure .........................................................................
552.4.2 Working range and type of motion ..............................................................
592.4.3 Risk of tipping/stability .............................................................................
602.4.4 The unit is sensitive to ESD .......................................................................
612.5 On-site installation ............................................................................................
612.5.1 Lifting the robot with fork lift accessory .......................................................
612.5.1.1 Fitting the fork lift accessory ..........................................................
642.5.1.2 Lifting the robot with fork lift truck ...................................................
672.5.2 Lifting the robot with lifting and turning tool ..................................................
722.5.3 Lifting robot with roundslings ....................................................................
742.5.4 Manually releasing the brakes ...................................................................
762.5.5 Lifting the base plate ................................................................................
772.5.6 Securing the base plate ............................................................................
822.5.7 Orienting and securing the robot ................................................................
862.5.8 Setting the system parameters for a suspended or tilted robot .........................
912.5.9 Fitting equipment on robot .......................................................................
992.5.10 Loads fitted to the robot, stopping time and braking distances .........................
1002.5.11 Signal lamp (option) .................................................................................
1012.6 Restricting the working range ..............................................................................
1012.6.1 Axes with restricted working range .............................................................
1022.6.2 Mechanically restricting the working range of axis 1 ......................................
1042.6.3 Mechanically restricting the working range of axis 3 ......................................
1062.7 Foundry Plus Cable guard (option) .......................................................................
1062.7.1 Installation of Foundry Plus Cable guard (option no. 908-1) .............................
1072.8 Electrical connections ........................................................................................
1072.8.1 Robot cabling and connection points ..........................................................
1102.9 Start of robot in cold environments ......................................................................
Product manual - IRB 6620 5
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© Copyright 2006-2020 ABB. All rights reserved.
Table of contents

1113 Maintenance
1113.1 Introduction ......................................................................................................
1123.2 Maintenance schedule and expected component life ...............................................
1123.2.1 Specification of maintenance intervals ........................................................
1133.2.2 Maintenance schedule .............................................................................
1153.2.3 Expected component life .........................................................................
1163.3 Inspection activities ...........................................................................................
1163.3.1 Inspecting the oil level in axis-1 gearbox .....................................................
1183.3.2 Inspecting the oil level in axis-2 gearbox .....................................................
1213.3.3 Inspecting the oil level in axis-3 gearbox .....................................................
1233.3.4 Inspecting the oil level in axis-4 gearbox .....................................................
1253.3.5 Inspecting the oil level in axis-5 gearbox .....................................................
1273.3.6 Inspecting the oil level in axis-6 gearbox .....................................................
1303.3.7 Inspecting, cable harness ........................................................................
1333.3.8 Inspecting the information labels ................................................................
1353.3.9 Inspecting the axis-1 mechanical stop pin ...................................................
1373.3.10 Inspecting the additional mechanical stops .................................................
1403.3.11 Inspecting the damper on axes 2-5 .............................................................
1423.3.12 Inspecting, signal lamp ............................................................................
1443.3.13 Inspection of air hoses (Foundry Prime) ......................................................
1453.4 Replacement/changing activities ..........................................................................
1453.4.1 Type of lubrication in gearboxes ................................................................
1473.4.2 Changing oil, axis-1 gearbox .....................................................................
1503.4.3 Changing oil, axis-2 gearbox .....................................................................
1533.4.4 Changing oil, axis-3 gearbox .....................................................................
1563.4.5 Changing oil, axis-4 gearbox .....................................................................
1593.4.6 Changing oil, axis-5 gearbox .....................................................................
1613.4.7 Changing oil, axis-6 gearbox .....................................................................
1643.4.8 Replacing the SMB battery ........................................................................
1683.5 Cleaning activities .............................................................................................
1683.5.1 Cleaning the IRB 6620 ..............................................................................
1714 Repair
1714.1 Introduction ......................................................................................................
1724.2 General procedures ...........................................................................................
1724.2.1 Performing a leak-down test ......................................................................
1734.2.2 Mounting instructions for bearings .............................................................
1754.2.3 Mounting instructions for sealings ..............................................................
1784.2.4 Cut the paint or surface on the robot before replacing parts ............................
1794.2.5 The brake release buttons may be jammed after service work .........................
1804.3 Complete robot .................................................................................................
1804.3.1 Replacement of cable harness, lower end (axes 1-2) ......................................
1874.3.2 Replacement of cable harness, upper end ...................................................
1974.3.3 Replacement of complete arm system .........................................................
2084.4 Upper and lower arm .........................................................................................
2084.4.1 Replacing the turning disk ........................................................................
2124.4.2 Replacement of wrist unit .........................................................................
2174.4.3 Replacement of the upper arm ...................................................................
2234.4.4 Replacement of lower arm ........................................................................
2284.5 Frame and base ................................................................................................
2284.5.1 Replacement of SMB unit .........................................................................
2334.5.2 Replacing the brake release board .............................................................
2374.6 Motors ............................................................................................................
2374.6.1 Replacement of motor, axis 1 ....................................................................
2424.6.2 Replacement of motor axis 2 .....................................................................
2484.6.3 Replacement of motor, axis 3 ....................................................................
2554.6.4 Replacement of motor, axis 4 ....................................................................
2604.6.5 Replacement of motor, axis 5 , IRB 6620/6620LX ...........................................
6 Product manual - IRB 6620
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© Copyright 2006-2020 ABB. All rights reserved.
Table of contents

2654.6.6 Replacement of motor, axis 6 ....................................................................
2724.7 Gearboxes .......................................................................................................
2724.7.1 Replacement gearbox axis 1 .....................................................................
2814.7.2 Replacement gearbox axis 2 .....................................................................
2884.7.3 Replacement of gearbox axis 3 ..................................................................
2924.7.4 Replacement of gearbox, axis 6 .................................................................
2995 Calibration
2995.1 Introduction to calibration ...................................................................................
2995.1.1 Introduction and calibration terminology ......................................................
3005.1.2 Calibration methods .................................................................................
3035.1.3 When to calibrate ...................................................................................
3045.2 Synchronization marks and axis movement directions .............................................
3045.2.1 Synchronization marks and synchronization position for axes .........................
3065.2.2 Calibration movement directions for all axes ................................................
3075.3 Updating revolution counters ...............................................................................
3115.4 Calibrating with Axis Calibration method ...............................................................
3115.4.1 Description of Axis Calibration ..................................................................
3145.4.2 Calibration tools for Axis Calibration ...........................................................
3165.4.3 Installation locations for the calibration tools ...............................................
3185.4.4 Axis Calibration - Running the calibration procedure ......................................
3235.4.5 Reference calibration ...............................................................................
3255.5 Calibrating with Calibration Pendulum method .......................................................
3265.6 Calibrating with Wrist Optimization method ...........................................................
3275.7 Verifying the calibration ......................................................................................
3285.8 Checking the synchronization position ..................................................................
3296 Decommissioning
3296.1 Environmental information ..................................................................................
3316.2 Scrapping of robot .............................................................................................
3337 Reference information
3337.1 Applicable standards .........................................................................................
3357.2 Unit conversion .................................................................................................
3367.3 Screw joints ....................................................................................................
3397.4 Weight specifications .........................................................................................
3407.5 Standard tools ..................................................................................................
3417.6 Special tools ....................................................................................................
3437.7 Lifting accessories and lifting instructions ..............................................................
3458 Spare part lists
3458.1 Spare part lists and illustrations ...........................................................................
3479 Circuit diagram
3479.1 Circuit diagrams ................................................................................................
349Index
Product manual - IRB 6620 7
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© Copyright 2006-2020 ABB. All rights reserved.
Table of contents

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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 6620. 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
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 on the robot. Based on available spare parts.
Repair
Continues on next page
Product manual - IRB 6620 9
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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
Complete spare part list and complete list of robot components,
shown in the exploded views.
Spare parts and exploded
views
Reference to the circuit diagram for the robot.Circuit diagrams
References
Document IDReference
3HAC025861-001Product specification - IRB 6620
3HAC049109-001Product manual, spare parts - IRB 6620
3HAC027309-001Product manual - DressPack/SpotPack IRB 6620
3HAC025090-001Circuit diagram - IRB 6620 / IRB 6620LX
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore
controller i
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-001Operating manual - Service Information System
3HAC051016-001Application manual - Additional axes and stand alone controller
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
3HAC030421-001Application manual - CalibWare Field
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition-
Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
A
Changes made in:
• Oil change Shell Tivela S 150 is changed to Kyodo Yushi TMO 150.
• New sections added "Robot transportation precautions" and "Securing
the robot".
• Foundry Plus option added.
B
Continues on next page
10 Product manual - IRB 6620
3HAC027151-001 Revision: W
© Copyright 2006-2020 ABB. All rights reserved.
Overview of this manual
Continued