ABB IRB 6660 User manual

ROBOTICS
Product manual
IRB 6660

Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012

Product manual
IRB 6660 - 100/3.3
IRB 6660 - 130/3.1
IRB 6660 - 205/1.9
IRC5
Document ID: 3HAC028197-001
Revision: S
© Copyright 2007-2018 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2007-2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
15Product documentation ....................................................................................................................
17How to read the product manual ......................................................................................................
191 Safety
191.1 General safety information ..................................................................................
191.1.1 Limitation of liability .................................................................................
211.1.2 Protective stop and emergency stop ...........................................................
221.2 Safety actions ...................................................................................................
221.2.1 Fire extinguishing ....................................................................................
231.2.2 Emergency release of the robot axes ..........................................................
241.2.3 Make sure that the main power has been switched off ....................................
251.3 Safety risks ......................................................................................................
251.3.1 Safety risks during installation and service work on robots ..............................
271.3.2 Moving robots are potentially lethal ............................................................
281.3.3 First test run may cause injury or damage ....................................................
291.3.4 Work inside the working range of the robot ..................................................
301.3.5 Enabling device and hold-to-run functionality ...............................................
311.3.6 Risks associated with live electric parts .......................................................
331.3.7 The unit is sensitive to ESD .......................................................................
341.3.8 Hot parts may cause burns .......................................................................
351.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
361.3.10 Brake testing ..........................................................................................
371.3.11 Safety risks during handling of batteries ......................................................
381.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................
401.4 Safety signals and symbols .................................................................................
401.4.1 Safety signals in the manual ......................................................................
421.4.2 Safety symbols on product labels ...............................................................
492 Installation and commissioning
492.1 Introduction ......................................................................................................
502.2 Unpacking .......................................................................................................
502.2.1 Pre-installation procedure .........................................................................
542.2.2 Working range and type of motion ..............................................................
582.2.3 Risk of tipping/stability .............................................................................
602.3 On-site installation ............................................................................................
602.3.1 Lifting robot with fork lift ...........................................................................
662.3.2 Lifting robot with roundslings ....................................................................
692.3.3 Lifting robot with lifting slings ....................................................................
732.3.4 Manually releasing the brakes ...................................................................
752.3.5 Lifting the base plate ................................................................................
762.3.6 Securing the base plate ............................................................................
812.3.7 Orienting and securing the robot ................................................................
842.3.8 Fitting equipment on robot .......................................................................
882.3.9 Installation of chip protection - IRB 6660 - 205/1.9 .........................................
902.3.10 Installation of cooling fan for motors (option) ................................................
972.3.11 Installation of Foundry Plus Cable guard (option no. 908-1) .............................
982.3.12 Loads fitted to the robot, stopping time and braking distances .........................
992.3.13 Signal lamp (option) .................................................................................
1002.4 Restricting the working range ..............................................................................
1002.4.1 Axes with restricted working range .............................................................
1012.4.2 Mechanically restricting the working range of axis 1 ......................................
1032.4.3 Extended working range, axis 1 (option 561-1) .............................................
1042.5 Electrical connections ........................................................................................
1042.5.1 Robot cabling and connection points ..........................................................
1072.6 Start of robot in cold environments ......................................................................
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1093 Maintenance
1093.1 Introduction ......................................................................................................
1103.2 Maintenance schedule and component life .............................................................
1103.2.1 Specification of maintenance intervals ........................................................
1113.2.2 Maintenance schedule .............................................................................
1133.2.3 Expected component life .........................................................................
1143.3 Inspection activities ...........................................................................................
1143.3.1 Inspecting the oil level in axis-1 gearbox .....................................................
1163.3.2 Inspecting, oil level gearbox axes 2 - 3 .......................................................
1193.3.3 Inspecting the oil level in axis-4 gearbox .....................................................
1213.3.4 Inspecting the oil level in axis-5 gearbox .....................................................
1233.3.5 Inspecting the oil level in axis-6 gearbox .....................................................
1263.3.6 Inspecting, balancing device bearings and piston rod guide ring ......................
1303.3.7 Inspection, cable harness .........................................................................
1343.3.8 Inspecting the information labels ................................................................
1363.3.9 Inspecting the axis-1 mechanical stop pin ...................................................
1383.3.10 Inspecting the additional mechanical stops .................................................
1403.3.11 Inspecting the damper on axes 2-5 .............................................................
1423.3.12 Inspecting, signal lamp (option) .................................................................
1443.4 Replacement/changing activities ..........................................................................
1443.4.1 Type of lubrication in gearboxes ................................................................
1463.4.2 Changing oil, axis-1 gearbox .....................................................................
1493.4.3 Changing oil, gearbox axes 2 and 3 ...........................................................
1533.4.4 Changing oil, axis-4 gearbox .....................................................................
1563.4.5 Changing oil, axis-5 gearbox .....................................................................
1593.4.6 Changing oil, axis-6 gearbox .....................................................................
1623.4.7 Replacing the SMB battery ........................................................................
1663.5 Lubrication activities ..........................................................................................
1663.5.1 Lubricating balancing device bearings and piston rod ....................................
1693.6 Cleaning activities .............................................................................................
1693.6.1 Cleaning the IRB 6660 ..............................................................................
1734 Repair
1734.1 Introduction ......................................................................................................
1744.2 General procedures ...........................................................................................
1744.2.1 Performing a leak-down test ......................................................................
1754.2.2 Mounting instructions for bearings .............................................................
1774.2.3 Mounting instructions for seals ..................................................................
1794.2.4 Cut the paint or surface on the robot before replacing parts ............................
1804.2.5 The brake release buttons may be jammed after service work .........................
1814.3 Complete robot .................................................................................................
1814.3.1 Replacement of cable harness, lower end (axes 1-3) ......................................
1894.3.2 Replacement of process cable package 1 - 3 MH ..........................................
1964.3.3 Replacement of cable harness, upper end ...................................................
2044.3.4 Replacement of cabling, axis 5 motor ..........................................................
2074.3.5 Replacement of complete arm system .........................................................
2174.4 Upper and lower arms ........................................................................................
2174.4.1 Replacing the turning disk ........................................................................
2214.4.2 Replacement of complete wrist unit ............................................................
2274.4.3 Replacement of upper arm ........................................................................
2384.4.4 Replacing the parallel rod .........................................................................
2444.4.5 Replacing the complete lower arm ..............................................................
2524.4.6 Replacement of parallel arm ......................................................................
2594.5 Frame and base ................................................................................................
2594.5.1 Replacing the SMB unit ............................................................................
2624.5.2 Replacing the brake release board .............................................................
2664.5.3 Replacing the balancing device ..................................................................
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Table of contents

2744.6 Motors ............................................................................................................
2744.6.1 Replacing motor, axis 1 ............................................................................
2814.6.2 Replacing motors, axes 2 and 3 .................................................................
2924.6.3 Replacement of motor, axis 4 ....................................................................
2974.6.4 Replacement of motor, axis 5 ...................................................................
3034.6.5 Replacement of motor, axis 6 ....................................................................
3114.7 Gearboxes .......................................................................................................
3114.7.1 Replacing the axis 1 gearbox .....................................................................
3244.7.2 Replacing the gearbox, axes 2- 3 ...............................................................
3364.7.3 Replacement of gearbox, axis 6 .................................................................
3415 Calibration
3415.1 Introduction to calibration ...................................................................................
3415.1.1 Introduction and calibration terminology ......................................................
3425.1.2 Calibration methods .................................................................................
3445.1.3 When to calibrate ...................................................................................
3455.2 Synchronization marks and axis movement directions .............................................
3455.2.1 Synchronization marks and synchronization position for axes .........................
3475.2.2 Calibration movement directions for all axes ................................................
3485.3 Updating revolution counters ...............................................................................
3525.4 Calibrating with Axis Calibration method ...............................................................
3525.4.1 Description of Axis Calibration ..................................................................
3545.4.2 Calibration tools for Axis Calibration ...........................................................
3565.4.3 Installation locations for the calibration tools ...............................................
3575.4.4 Axis Calibration - Running the calibration procedure ......................................
3635.5 Calibrating with Calibration Pendulum method ........................................................
3645.6 Verifying the calibration ......................................................................................
3655.7 Checking the synchronization position ..................................................................
3676 Decommissioning
3676.1 Introduction ......................................................................................................
3686.2 Environmental information ..................................................................................
3696.3 Scrapping of robot .............................................................................................
3706.4 Decommissioning of balancing device ...................................................................
3737 Reference information
3737.1 Introduction ......................................................................................................
3747.2 Applicable standards .........................................................................................
3767.3 Unit conversion .................................................................................................
3777.4 Screw joints ....................................................................................................
3807.5 Weight specifications .........................................................................................
3817.6 Standard tools ..................................................................................................
3827.7 Special tools ....................................................................................................
3857.8 Lifting accessories and lifting instructions ..............................................................
3878 Spare part lists
3878.1 Spare part lists and illustrations ...........................................................................
3899 Circuit diagram
3899.1 Circuit diagrams ................................................................................................
391Index
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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.
The manual also contains reference information for all procedures detailed in the
manual.
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 6660. 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 the 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
Continues on next page
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Overview of this manual

ContentsChapter
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
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 exploded views.
Spare part / part list
Detailed illustrations of the robot with reference numbers to the
part list.
Exploded views
Reference to the circuit diagram for the robot..Circuit diagram
References
Document IDReference
3HAC028207-001Product specification - IRB 6660
3HAC049112-001Product manual, spare parts - IRB 6660
3HAC029940-001Circuit diagram - DressPack 6660
Circuit diagram - IRB 6660Circuit diagram - IRB 6660
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
3HAC050996-001Application manual - Electronic Position Switches
3HAC030421-001Application manual - CalibWare Field 5.0
Revisions
DescriptionRevision
First edition-
This revision includes the following additions and/or changes:A
• Robot version IRB 6660 - 205/1.9 added which includes new upper arm
and new lower arm, as well as Chip protection.
• Process cable package added.
• Option Base spacers no longer available for this robot model. Section
is removed from the manual.
•Prerequisites in section Overview changed.
• Oil change intervals for Shell Tivela S 150 is changed.
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
• New product name Mobilgear 600 XP 320 (old name Mobile Gearlube
X 320). Art. no. remains the same.
• Procedure for Process cable package 1-3 MH added.
This revision includes the following additions and/or changes:B
• The product name RobotStudio Online is changed to RobotStudio.
• Section "WARNING! - Mixed oils may cause severe damage to gear-
boxes" in chapter Safety, has been integrated in section "Type of oil
in gearboxes" in Maintenance chapter.
• The oil Shell Tivela S150 has been replaced by Kyodo Yushi TMO150.
• Section Type of oil in gearboxes in chapter Maintenance has been
updated according to changes made in oil types.
• 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.
This revision include the following addition:C
• New WARNING! added in chapter Safety section Work inside the ro-
bot´s working range.
• New WARNING! added in Safety chapter section WARNING! - Safety
risks during work with gearbox oil.
• The text in the introductions to chapters Installation,Maintenance and
Repair has been updated concerning the robot being connected to
earth when power connected.
• Section Expected component life in chapter Maintenance : The lifetime
of certain parts has been updated.
• Section Foundry Plus,Cable guard added to chapter Installation.
This revision includes the following additions and/or changes:D
• The lifetime of certain parts has been updated, see Expected compon-
ent life on page 113.
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 389.
• List of standards updated, see Applicable standards on page 374.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 40.
• New safety labels on the manipulators, see Safety symbols on product
labels on page 42.
• Revised terminology: robot replaced with manipulator.
This revision includes the following updates:E
• Maximum deviation changed, see Securing the base plate on page 76.
This revision includes following additions and/or changes:F
• Removed information about lubricating attachment screws, section
Inspecting the additional mechanical stops on page 138.
• Changed tightening torque of fork lift adapters, from 60 Nm to 270 Nm,
see section Lifting robot with fork lift on page 62.
• Information about restricting and extending the working range of axis
1 is now separated, see Mechanically restricting the working range of
Continues on next page
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Continued

DescriptionRevision
axis 1 on page 101 and the new section Extended working range, axis
1 (option 561-1) on page 103. Also added signal about option 561-1 in
section Inspecting the axis-1 mechanical stop pin on page 136.
This revision includes the following updates:G
• Added section Extended working range, axis 1 (option 561-1) on
page 103.
• A new block, about general illustrations, added in section How to read
the product manual on page 17.
• Added instructions for securing parallel arm and lower arm to each
other before removing the lower arm, see Replacing the complete lower
arm on page 244.
•Added guide sleeves to hold the axes 2/3 sealing in place when refitting
the lower arm, see Replacing the complete lower arm on page 244.
• Made minor corrections and improvements in the complete instruction
for how to replace the lower arm system, see Replacing the complete
lower arm on page 244.
• Made minor corrections and improvements in the complete instruction
for how to replace the parallel arm, see Replacement of parallel arm
on page 252.
• Made minor corrections and improvements in the complete instruction
for how to replace the axis 1 gearbox, see Replacing the axis 1 gearbox
on page 311.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 377.
• Added Safety risks during handling of batteries on page 37.
•The maximum allowed deviation in levelity of the base plate is changed,
see Securing the base plate on page 76.
• 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 76.
• Corrections and improvements are made in the instruction for how to
replace the axis-2 and axis-3 gearbox, see Replacing the gearbox, axes
2- 3 on page 324.
• 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 144.
• Corrected the article number for the o-ring in axis-6 gearbox, see Re-
placement of gearbox, axis 6 on page 336.
This revision includes the following updates:H
• New variant IRB 6660 - 100/3.3 is added.
• Added turning radius and wrist center positions to the working range
information, see Working range and type of motion on page 54.
• New spare part number for the cable harness for robot variant IRB
6660 - 130/3.1, see Spare parts - cable harness.
• Added complete axis 4 and upper arm extenders to the spare part list,
and removed upper arm and cooling elements as spare parts, see
Spare parts - upper arm.
• Corrected the method of inspecting oil level in the axis-6 gearbox, see
Inspecting the oil level in axis-6 gearbox on page 123.
• Added o-rings to required equipment lists in Replacing motor, axis 1
on page 274 and Replacing motors, axes 2 and 3 on page 281.
• Corrected the position numbers of axis-3 motor and its attachments,
see Spare parts - frame to lower arm.
• A new SMB unit and battery is introduced, with longer battery lifetime.
Continues on next page
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Continued

DescriptionRevision
This revision includes the following updates:J
• Instruction for inspection of oil level updated.
• Added cabling to cooling fan for axis-1 and axis-2 motors.
• Added information about risks when scrapping a decommissioned ro-
bot, see Scrapping of robot on page 369.
•Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare
parts - IRB 6660
This revision includes the following updates:K
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 76.
• Changed dimension of cable holder carrier screw, see Replacement
of cable harness, upper end on page 196.
•Information about option Foundry Plus implemented in chapter Repair.
• Added tightening torque for R1.SMB and 7th axis connector, ses Re-
placement of cable harness, lower end (axes 1-3) on page 181.
• Minor corrections.
This revision includes the following updates:L
• Illustrations of SMB battery RMU improved.
This revision includes the following updates:M
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 341.
Published in release R16.2. The following updates are made in this revision:N
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 76.
• Corrections due to updates in terminology.
• Information about grounding point added. See Robot cabling and
connection points on page 104.
Published in release R17.2. The following updates are made in this revision:P
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Bending radius of 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 107 added.
• Updated information regarding replacement of brake release board.
•Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Updated information regarding replacing the balancing device.
Published in release R18.1. The following updates are made in this revision:Q
•Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 354.
• Added sections in General procedures.
• Safety restructured.
• Updated spare parts number brake release board (is DSQC1050, was
DSQC563)
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calib-
ration values.
•Moved position of customer cabling plate at robot base to new location,
see Replacement of process cable package 1 - 3 MH on page 189.
Continues on next page
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Continued

DescriptionRevision
• Information about myABB Business Portal added.
•Changed direction of installed cooling fan on axis-2 motor and removed
a faulty image showing the design of the cooling fan. Also added de-
tailed images to installation procedure for the fan.
Published in release R18.2. The following updates are made in this revision:R
• Removed doubled information.
Published in release R18.2. The following updates are made in this revision:S
• Updated references.
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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 General 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 complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/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 made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
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.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
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.
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Product manual - IRB 6660 19
3HAC028197-001 Revision: S
© Copyright 2007-2018 ABB. All rights reserved.
1 Safety
1.1.1 Limitation of liability

The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed 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.
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.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB, it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength of the robot could
be affected.
20 Product manual - IRB 6660
3HAC028197-001 Revision: S
© Copyright 2007-2018 ABB. All rights reserved.
1 Safety
1.1.1 Limitation of liability
Continued