ABB IRB 6620LX User manual

ROBOTICS
Product manual
DressPack/SpotPack IRB 6620LX

Trace back information:
Workspace R17-2 version a11
Checked in 2017-09-20
Skribenta version 5.1.011

Product manual
DressPack/SpotPack IRB 6620LX
IRC5
Document ID: 3HAC055327-001
Revision: A
© Copyright 2016-2017 ABB. All rights reserved.

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 2016-2017 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
7Overview of this manual ...................................................................................................................
9Product documentation, IRC5 ..........................................................................................................
11Product name principles ...................................................................................................................
131 Safety
131.1 Introduction to safety information ......................................................................... 141.2 General safety information .................................................................................. 141.2.1 Introduction to general safety information .................................................... 151.2.2 Safety in the robot system ........................................................................ 171.2.3 Protective stop and emergency stop ........................................................... 181.2.4 Safety risks ............................................................................................ 181.2.4.1 Safety risks during installation and service work on manipulators ......... 211.2.4.2 CAUTION - Hot parts may cause burns! ........................................... 221.2.4.3 Safety risks related to tools/work pieces .......................................... 231.2.4.4 Safety risks related to pneumatic/hydraulic systems .......................... 241.2.4.5 Safety risks during operational disturbances ..................................... 251.2.4.6 Risks associated with live electric parts ........................................... 271.2.5 Safety actions ......................................................................................... 271.2.5.1 Safety fence dimensions ............................................................... 281.2.5.2 Fire extinguishing ........................................................................ 291.2.5.3 Emergency release of the robot arm ............................................... 301.2.5.4 Brake testing .............................................................................. 311.2.5.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 321.2.5.6 Enabling device and hold-to-run functionality .................................... 331.2.5.7 Work inside the working range of the robot ....................................... 341.2.5.8 Signal lamp (optional) ................................................................... 351.3 Safety signals and symbols ................................................................................. 351.3.1 Safety signals in the manual ...................................................................... 371.3.2 Safety symbols on product labels ............................................................... 431.4 Safety related instructions .................................................................................. 431.4.1 DANGER - Moving robots are potentially lethal! ............................................ 441.4.2 DANGER - First test run may cause injury or damage! ................................... 451.4.3 WARNING - The brake release buttons may be jammed after service work ........ 461.4.4 DANGER - Make sure that the main power has been switched off! .................... 481.4.5 WARNING - The unit is sensitive to ESD! ..................................................... 501.4.6 WARNING - Safety risks during handling of batteries ..................................... 511.4.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
532 Installation
532.1 Introduction ...................................................................................................... 542.2 DressPack cable package ................................................................................... 542.2.1 Overview ............................................................................................... 562.2.2 Fitting the lower arm cable package - IRBDP MH 3 LE .................................... 622.2.3 Fitting the attachments of the upper arm cable package - IRBDP MH 3 UE ......... 662.2.4 Fitting the upper arm cable package - IRBDP MH 3 UE ................................... 712.2.5 Inspection, DressPack lower arm ............................................................... 722.2.6 Inspection, DressPack upper arm ............................................................... 742.3 DressPack adjustments ...................................................................................... 742.3.1 Adjustments of the cable package - IRBDP MH3 UE ...................................... 762.3.2 Inspection during programming and test-running .......................................... 772.4 DressPack Armload parameters ........................................................................... 792.5 DressPack floor ................................................................................................ 792.5.1 Installation of DressPack floor ................................................................... 822.5.2 Inspection, DressPack floor .......................................................................
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Table of contents

833 Maintenance
833.1 Introduction ...................................................................................................... 843.2 Maintenance schedule and component lives .......................................................... 843.2.1 Maintenance schedule ............................................................................. 863.3 Inspection activities ........................................................................................... 863.3.1 Preventive inspection of all cables, DressPack ............................................. 883.3.2 Preventive inspection, DressPack upper end ................................................
914 Repair
914.1 Introduction ...................................................................................................... 924.2 DressPack cable package ................................................................................... 924.2.1 Replacement of the lower arm cable package - IRBDP MH 3 LE ....................... 984.2.2 Replacement of upper arm cable package - IRBDP MH 3 UE ...........................
1015 Decommissioning
1015.1 Environmental information ..................................................................................
1036 Reference information
1036.1 Introduction ...................................................................................................... 1046.2 Applicable standards ......................................................................................... 1066.3 Unit conversion ................................................................................................. 1076.4 Screw joints .................................................................................................... 1106.5 Weight specifications ......................................................................................... 1116.6 Toolkits, DressPack/SpotPack ............................................................................. 1126.7 Lifting accessories and lifting instructions ..............................................................
1137 Spare parts
1137.1 Introduction ...................................................................................................... 1147.2 DressPack IRB 6620LX ...................................................................................... 1147.2.1 DressPack cable package lower arm - IRBDP MH 3 LE ................................... 1157.2.2 DressPack cable package upper arm - IRBDP MH 3 UE .................................. 1167.2.3 Connection kits ....................................................................................... 1177.2.4 7:th axis to base ...................................................................................... 1187.2.5 Customer signal/power .............................................................................
119Index
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Table of contents

Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical work for DressPack/SpotPack systems
• maintenance of the DressPack/SpotPack systems
• mechanical and electrical repair of the DressPack/SpotPack systems.
The manual also contains reference information for all procedures detailed in this
manual.
Usage
This manual shall be used during:
• installation on the DressPack/SpotPack system
• maintenance on the DressPack/SpotPack system
• repair work on the DressPack/SpotPack system.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A 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.
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 the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Safety
Descriptions of mechanical installation and electrical connections.Installation
Descriptions of all required preventive maintenance procedures
including intervals.
Maintenance
Descriptions of all recommended repair procedures.Repair
Environmental information about the components.Decommissioning
Useful information when performing installation, maintenance or
repair work. Includes lists of necessary tools, additional docu-
ments, safety standards, etc.
Reference information
Complete spare part list incuding wear parts shown in exploded
views.
Spare parts
References to article numbers for circuit diagrams.Circuit diagrams
Continues on next page
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Overview of this manual

References
Document IDReference
3HAC031045-001Operating manual - General safety information i
3HAC025861-001Product specification - IRB 6620
3HAC035737-001Product manual - IRB 6620LX
3HAC021313-001Product manual - IRC5
3HAC026136-001Circuit diagram - DressPack 6620
3HAC026208-001Circuit diagram - SpotPack 6620
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC050948-001Technical reference manual - System parameters
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Note
The document numbers that are listed for software documents are valid for
RobotWare 6. Equivalent documents are available for RobotWare 5.
Revisions
DescriptionRevision
First edition.-
Published in release R17.2. The following updates are done in this revision:
• Updated list of applicable standards.
A
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Overview of this manual
Continued

Product documentation, IRC5
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 listed can be ordered from ABB on a DVD. The documents listed
are valid for IRC5 robot systems.
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 exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products.
•Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
•Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
•Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
•Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Continues on next page
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Product documentation, IRC5

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, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
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.
The group of manuals includes (among others):
•Operating manual - Emergency safety information
•Operating manual - General safety information
•Operating manual - Getting started, IRC5 and RobotStudio
•Operating manual - IRC5 Integrator's guide
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Troubleshooting IRC5
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Product documentation, IRC5
Continued

Product name principles
General
The different robots have a wide range of options. In many cases the option name
gives a good explanation of its content. In some cases there is a need to add more
information in the product name in order to clearly show a certain variant and to
avoid misunderstandings. Hence a complementary naming standard is used.
The family name of the options is DressPack (that is customer cables and hoses
from the controller to the robot’s axis 6, divided in different sections).
DressPack parts
DressPack parts that are assembled on the robot are called:
•IRBDP (IRB DressPack)
Main application
The DressPack has been prepared for two main applications:
ApplicationProduct name
Material handlingMH
Spot weldingSW
Generations
The different generations of a DressPack is indicated with a generation number.
The number indicates the different design of each generation. (Some generations
might not be available since it has been phased out).
•1,2,3etc
Sections
The DressPack on the robot is supplied in different sections:
SectionProduct name
Lower DressPack sectionL
Upper DressPack sectionU
Continuous DressPackC
(DressPack without an intermediate connection point)
Routing
The DressPack can be routed in different ways:
RoutingProduct name
Integrated DressPackI
The main parts are integrated within the robot structure.
External DressPackE
The main parts are routed outside, on the robot structure.
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Product name principles

Examples
•IRBDP MH 3 UE = IRB DressPack / Material handling application / Generation
3 / Upper arm DressPack section / External routing
•IRBDP SW 4 UI = IRB DressPack / Spot welding application / Generation 4
/ Upper arm DressPack section / Internal routing
•IRBDP SW 2 LE = IRB DressPack / Spot welding application / Generation 2
/ Lower arm DressPack section / External routing
•IRBDP SW 2 CE = IRB DressPack / Spot welding application / Generation 2
/ Continuos DressPack section / External routing
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Product name principles
Continued

1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into the following categories:
• General safety aspects, important to attend to before performing any service
work on the robot. These are applicable for all service work and are found
in General safety information on page 14.
• Safety signals and symbols shown in the manual and on the robot, warning
for different types of dangers, are found in Safety signals and symbols on
page 35.
• Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 43.
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1 Safety
1.1 Introduction to safety information

1.2 General safety information
1.2.1 Introduction to general safety information
Definitions
This section details general safety information for personnel performing installation,
maintenance and repair work.
Sections
The general safety information is divided into the following sections.
Examples of contentSection
This section describes the following:
• safety, service
• limitation of liability
• related information
Safety in the robot system on page 15
This section describes protective stop and
emergency stop.
Protective stop and emergency stop on
page 17
This section lists dangers relevant when work-
ing with the product. The dangers are split into
different categories.
• safety risks during installation or service
• risks associated with live electrical parts
Safety risks on page 18
This section describes actions which may be
taken to remedy or avoid dangers.
• fire extinguishing
• safe use of the teach pendant or jogging
device
Safety actions on page 27
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1 Safety
1.2.1 Introduction to general safety information

1.2.2 Safety in the robot system
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system are
designed and installed correctly. Personnel working with robot must be familiar
with the operation and handling of the industrial robot as described in the applicable
documents, for example:
•Operating manual - IRC5 with FlexPendant
•Operating manual - General safety information I
•Product manual
IThis manual contains all safety instructions from the product manuals for the robots and the
controllers.
The robot system shall be designed and constructed in such a way as to allow safe
access to all areas where intervention is necessary during operation, adjustment,
and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
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.
Related information
SectionDetailed in documentType of information
Installation and
commissioning
Product manual for the robotInstallation of safety devices
Operating modesOperating manual - IRC5 with FlexPend-
ant
Changing operating modes
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1 Safety
1.2.2 Safety in the robot system

SectionDetailed in documentType of information
Installation and
commissioning
Product manual for the robotRestricting the working space
Load diagramsProduct specification for the robotLoad limits for tools and
workpieces
Application manual - Functional safety
and SafeMove
Configuration of safety mod-
ule (requires Functional safety
options)
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1 Safety
1.2.2 Safety in the robot system
Continued

1.2.3 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
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1 Safety
1.2.3 Protective stop and emergency stop

1.2.4 Safety risks
1.2.4.1 Safety risks during installation and service work on manipulators
Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the manipulator.
These safety instructions have to be read and followed by any person who deals
with the installation and maintenance of the manipulator. Only persons who know
the robot and are trained in the operation and handling of the manipulator are
allowed to maintain the manipulator. Persons who are under the influence of alcohol,
drugs or any other intoxicating substances are not allowed to install, maintain,
repair, or use the manipulator.
The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
General risks during installation and service
• The instructions in the product manual in the chapters Installation and
commissioning, and Repair must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so
that the robot can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
Spare parts and special equipment
ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. ABB is not liable for damages caused by
the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the robot system.
Personal protective equipment
Always use suitable personal protective equipment, based on the risk assessment
for the robot installation.
Nation/region specific regulations
To prevent injuries and damages during the installation of the robot, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be
complied with.
Continues on next page
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1 Safety
1.2.4.1 Safety risks during installation and service work on manipulators

Non-voltage related risks
• Make sure that no one else can turn on the power to the controller and robot
while you are working with the system. A good method is to always lock the
main switch on the controller cabinet with a safety lock.
• Safety zones, which must be crossed before admittance, must be set up in
front of the robot's working space. Light beams or sensitive mats are suitable
devices.
• Turntables or the like should be used to keep the operator out of the robot's
working space.
• If the robot is installed at a height, hanging, or other than standing directly
on the floor, there may be additional risks than those for a robot standing
directly on the floor.
• The axes are affected by the force of gravity when the brakes are released.
In addition to the risk of being hit by moving robot parts, there is a risk of
being crushed by the parallel arm (if there is one).
• Energy stored in the robot for the purpose of counterbalancing certain axes
may be released if the robot, or parts thereof, are dismantled.
•When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, which means, do not climb on the motors
or other parts during service work. There is a serious risk of slipping because
of the high temperature of the motors and oil spills that can occur on the
robot. There is also a risk of the robot being damaged.
To be observed by the supplier of the complete system
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Complete robot
DescriptionSafety risk
CAUTION
Motors and gearboxes are HOT after running
the robot! Touching motors and gearboxes
may result in burns!
With a higher environment temperature, more
surfaces on the manipulator will get HOT and
may also result in burns.
Hot components!
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1 Safety
1.2.4.1 Safety risks during installation and service work on manipulators
Continued

DescriptionSafety risk
WARNING
Take any necessary measures to ensure that
the robot does not collapse as parts are re-
moved. For example, secure the lower arm
according to the repair instruction if removing
the axis-2 motor.
Removed parts may result in collapse of
the robot!
WARNING
If the internal cables for the measurement
system have been disconnected during repair
or maintenance, then the revolution counters
must be updated.
Removed cables to the measurement sys-
tem
Cabling
DescriptionSafety risk
CAUTION
The cable packages are sensitive to mechan-
ical damage. Handle the cable packages and
the connectors with care in order to avoid
damage.
Cable packages are sensitive to mechanical
damage!
Gearboxes and motors
DescriptionSafety risk
CAUTION
Whenever parting/mating motor and gearbox,
the gears may be damaged if excessive force
is used!
Gears may be damaged if excessive force
is used!
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1 Safety
1.2.4.1 Safety risks during installation and service work on manipulators
Continued