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 ......................................................................
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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 ...........................................
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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
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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
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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
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Continued

DescriptionRevision
This revision includes the following additions and/or changes:
• Section What is an emergency stop? added to chapter Safety‘
• Section Maintenance schedule in chapter Maintenance: Intervals for
inspection activities and oilchanges have been revised
• Section Maintenance schedule in chapter Maintenance: Overhaul of
robot is new
•Section Maintenance schedule in chapter Maintenance: The information
about Service Information System (SIS) has been updated
• Section Maintenance schedule in chapter Maintenance: Intervals for
replacement of battery pack changed
•Section Expected lifetime in chapter Maintenance: The lifetime of certain
parts has been revised
• Section Cleaning of robot updated
C
This revision includes the following additions and/or changes:
• Section Lifting and turning tool added to the Installation chapter.
• Section Foundry Plus,Cable guard added to chapter Installation.
• Updated spare part numbers in lists for cable harness and wrist.
D
This revision includes the following additions and/or changes:
• Added oil levels for tilted robots, see Inspecting the oil level in axis-1
gearbox on page 116, and Inspecting the oil level in axis-2 gearbox on
page 118.
• Corrected item number reference in part list, see Spare parts - Upper
arm in Product manual, spare parts - IRB 6620.
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 347.
• List of standards updated, see Applicable standards on page 333.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 21.
• New safety labels on the manipulators, see Safety symbols on manipu-
lator labels on page 23.
• Revised terminology: robot replaced with manipulator.
E
This revision includes the following updates:
• Maximum deviation changed, see Securing the base plate on page 77.
•Updated instructions for replacing motor axis 6 on Foundry Plus robots.
F
This revision includes following additions and/or changes:
• Removed information about lubricating attachment screws, section In-
specting the additional mechanical stops on page 137.
G
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Continued

DescriptionRevision
This revision includes the following updates:
• A new block, about general illustrations, added in section How to read
the product manual on page 17.
• Robot designations are adjusted in sub-headings in section Robot
transportation precautions on page 42.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 336.
• Added information about batteries.
•The maximum allowed deviation in levelity of the base plate is changed,
see Securing the base plate on page 77.
• Added information about how to check oil level and change oil in the
axis-1 gearbox of a suspended robot, see Inspecting the oil level in
axis-1 gearbox on page 116 and Changing oil, axis-1 gearbox on page 147.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed to
european standard C25/C30 (previously Swedish standard K25/K30),
see Securing the base plate on page 77.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of oil
in gearboxes on page 145.
• Added section Inspection of air hoses (Foundry Prime) on page 144.
H
This revision includes the following updates:
• Corrected location of label for lifting, see Inspecting the information
labels on page 133.
• Spare part number for wrist (standard) was wrong. Has been corrected.
• A new SMB unit and battery is introduced, with longer battery lifetime.
J
This revision includes the following updates:
• New instruction for inspection of oil level.
•Added information about risks when scrapping a decommissioned robot,
see Scrapping of robot on page 331.
•Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare
parts - IRB 6620.
K
This revision includes the following updates:
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 77.
• Changed dimension of cable holder carrier screw, see Replacement of
cable harness, upper end on page 187.
• Added tightening torque for R1.SMB and 7th axis connector, ses Re-
placement of cable harness, lower end (axes 1-2) on page 180.
• Minor corrections.
L
This revision includes the following updates:
• Split fork lift accessory instruction in two sections.
• Improvements Foundry Plus (retrofit sets) added throughout the
manual. New wrist cover and improved sealing on arm house cover,
and more.
• Minor corrections.
M
This revision includes the following updates:
• Minor corrections.
N
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Continued

DescriptionRevision
This revision includes the following updates:
• Minor corrections.
• Description about the revolution indicator.
• Changed filling oil plug to inspection oil plug in inspection of level axis
3.
• Information updated and added in the calibration chapter.
P
This revision includes the following updates:
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 299.
Q
Published in release R16.2. The following updates are made in this revision:
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 77.
• Corrections due to updates in terminology.
R
Published in release R17.2. The following updates are made in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Section Start of robot in cold environments on page 110 added.
• Updated information regarding replacement of brake release board.
•Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Definition of reference calibration clarified.
S
Published in release R18.1. The following updates are made in this revision:
•Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 314.
• Added sections in General procedures on page 172.
• Safety restructured.
• New spare part number brake release board (was DSQC563,
3HAC16035-1)
• Corrections of required equipment, see Mechanically restricting the
working range of axis 1 on page 102.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calibra-
tion values.
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
T
Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint or sur-
face on the robot before replacing parts on page 178.
U
Published in release 19C. The following updates are made in this revision:
• Information about a mandatory check of cable harness added to Updat-
ing revolution counters on page 307.
• Removed information regarding the revolution indicator throughout the
manual.
• Note added about the need to calibrate if the robot is other than floor
mounted. See When to calibrate on page 303.
V
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Continued

DescriptionRevision
Published in release 20B. The following updates are made in this revision:
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 175.
•Clarified text about position of robot and added table with dependencies
between axes during Axis Calibration.
• Added information about Wrist Optimization in calibration chapter.
• Replaced article number and name of grease, previously 3HAB3537-1.
W
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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.
Continues on next page
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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 references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
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 19.
Illustrations
The robot 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 robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual

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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